Wall system

ABSTRACT

The present invention relates to decorative and structural blocks designed to be installed as skirting structures for buildings, elevated structures and structural elements such as posts. More particularly, the present invention relates to a system that uses specifically designed and manufactured masonry blocks that are used in conjunction with specifically designed support beams and/or brackets to provide durable, attractive, easy to assemble surfaces or skirting structures. The blocks are shaped to be stacked in vertically independent, self-supporting columns, strengthened and linked together by specially shaped, lightweight, lateral support beams positioned between adjacent columns, and which may be attached directly or indirectly to a sub-structure.

RELATED APPLICATIONS

This application is a continuation of application Ser. No. 10/395,608,filed on Mar. 24, 2003, entitled “Mortarless Wall Structure,” andpublished as US Publication No. 2003/0188497 on Oct. 9, 2003 which is acontinuation in part of application Ser. No. 10/015,052, filed Dec. 11,2001, entitled “Mortarless Wall Structure,” and issued as U.S. Pat. No.6,691,471 on Feb. 17, 2004, which is a continuation in part ofapplication Ser. No. 09/547,206, filed Apr. 12, 2000, entitled “SkirtingWall System,” and issued as U.S. Pat. No. 6,374,552 on Apr. 23, 2002.This application is also a continuation in part of application Ser. No.10/363,999, filed Apr. 12, 2001, entitled “Mortarless Wall Structure,”and published as US Publication No. 2004/0006945 on Jan. 15, 2004, whichis a continuation in part of application Ser. No. 09/547,206, filed Apr.12, 2000, entitled “Skirting Wall System,” and issued as U.S. Pat. No.6,374,552 on Apr. 23, 2002. This application also claims priority to PCTapplication Serial No. PCT/US01/11957 filed on Apr. 12, 2001, entitled“Wall Structure,” and PCT application Serial No. PCT/US00/25791 filed onSep. 20, 2000, entitled “Wall Structure,” and all of which are herebyincorporated by reference.

FIELD OF THE INVENTION

The present invention relates to decorative and structural blocksdesigned to be installed as exterior and interior walls for buildings.More particularly, the present invention relates to a system that usesspecifically designed and manufactured masonry blocks that are used inconjunction with specifically designed support beams and/or brackets toprovide durable, attractive, easy to assemble surfaces to a wide varietyof buildings, structures, and structural elements.

BACKGROUND OF THE INVENTION

Transportable structures such as mobile homes, trailer homes, modularhomes and recreational vehicles, by their very nature, are usually notintended to be built upon a conventional foundation. Rather, they arebrought or driven to a location where they may remain for indeterminateperiods of time. Often, over an extended period at a particular site,such structures may start to settle differentially onto or in the grounddue to factors such as deflating tires or local variations in soilbearing capacities. Additionally, factors such as erosion andfreeze-thaw cycles may also cause such structures to shift and/or tilt.In order to prevent such unwanted movement and ensure that a structureis level regardless of the ground's topography, the structures are oftenplaced on stilts that extend from the structure or upon piles thatextend from the ground, or even on isolated footings that distribute theweight of a structure over a relatively large surface area. While thissolves the aforementioned problem of shifting/or sinking it oftenresults in an unsightly visible gap in the area between the ground andthe bottom of the structure.

Various attempts to cover the unsightly gap have included the use ofplants, natural material such as rocks and wood and manmade productssuch as cement, masonry and plastics. These attempts have proven to beeither prohibitively expensive, difficult to install and/or disassemble,or unattractive and unable to withstand sustained exposure to nature'selements. Attempts that tend to be prohibitively expensive or difficultto install include, for example, wall structures constructed of large,custom-made, cement slabs having decorative faces, and standard masonryblocks held together with mortar. Attempts that fall into the lattercategory include such relatively fragile and easily breakable productsas wooden or plastic lattices, and synthetic panels designed to simulatestones or bricks.

Consequently, there is a need for an easy to assemble and/or dissemble,lightweight and sturdy, inexpensive wall structure for covering the gapbetween the ground and an elevated structure such as a mobile home.

In other applications, where brick, stone, or concrete is used as veneeror fascia, for fencing, and as load-bearing and non load-bearing walls,etc., these structures are constructed with an eye towards permanence.That is, the structures are not meant to be easily dismantled. Thismeans that the component parts are often able to interconnect with eachother and/or with a support framework in some fashion. This usuallyentails the use of robust connections such as mechanical fasteners,adhesives, cement, or the like. For example, many types of veneers aretypically coated with adhesive or cementitious material to enable themto be securely and directly bonded to a structure. Or, as anotherexample, walls may be constructed in a conventional manner with blocksand mortar.

Alternatively, wall structures may comprise heavy, interlocking blocksthat rely on size and weight to achieve some measure of permanence. Asone may well imagine, each of the aforementioned structures would bedifficult and time consuming to reconfigure, remove, or repair shouldthe need arise. And while the construction of some of these structurestypically requires specialized knowledge, skills, and tools to achieve,it will be appreciated that disassembly may require other, additionalspecialized knowledge, skills, and tools to achieve. In light of theseshortcomings, there is an additional need for a wall structure that maybe easily assembled, disassembled and rebuilt or reconfigured by anunskilled user without damage to the constituent parts of the wallstructure and which may be used as a veneer, fascia, cladding, fence, oras a load-bearing or non load-bearing wall.

The present invention provides a solution to these needs and otherproblems, and offers other advantages over the prior art.

SUMMARY OF THE INVENTION

Generally, the present invention provides a system by which structuresmay be provided with durable, easy to assemble externally facingsurfaces, which are generally vertical and which may be used in a widevariety of applications. The system utilizes a series of particularlyconfigured blocks that may be operatively connected to the structures bybeams and/or brackets. One embodiment of the present invention providesa block wall system for use in skirting elevated structures. The blocksare shaped to be stacked in vertically independent, self-supportingcolumns, strengthened and linked together by specially shaped,lightweight, lateral support beams positioned between adjacent columns,and which may be stabilized by one or more inverted u-shaped bracketswhich are attached at or near the bottom of an elevated structure. In analternative embodiment, a u-shaped bracket is provided with an arm thatis rotatably attached thereto and which is movable into a position thatfacilitates attachment to a generally vertical surface. In anotherembodiment, the blocks are configured so that lateral support beams maybe positioned not only between adjacent columns but also at intermediatepositions along the block as well. In another embodiment, the lateralsupport beam is configured so that it can be movably coupled to abracket, which may be attached to an existing structure.

One embodiment of the block comprises a front face, a rear face, top andbottom surfaces, and side surfaces, and each side surface includes anoutwardly opening, vertically oriented groove for receiving a portion ofa support beam. The top and bottom surfaces are configured to facilitatea stacking relationship between adjacent courses of blocks such thatthey are generally coplanar. This relationship is most easily achievedby making the top and bottom surfaces substantially collateral, planarand relatively perpendicular to rear and/or front faces. Anotherembodiment of the block includes the provision of externally formedchannels that are configured and arranged to prevent moisture fromforming and collecting at the rear face of the block. Another embodimentof the block includes at least one through hole or aperture that issubstantially aligned with outwardly opening, vertically orientedgrooves in the side surfaces of a block. As will be explained later, thethrough holes or apertures facilitate use with support beams in avariety of applications. Another embodiment of the block has viewablesurfaces or facings that are angled with respect to each other and whichfacilitate the formation of closed structures.

One purpose of the beams is to keep vertically stacked, self-supportingcolumns of blocks from buckling when subjected to a force normal to theplane of the column. This strengthening is accomplished providing thebeams with lateral extensions or ribs that are configured to be receivedin aligned grooves at the sides of the vertically stacked blocks.Another purpose of the beams is to link adjacent columns of blockstogether in a colonnade-like arrangement to form a wall structure. Thisis also achieved with the aforementioned lateral extensions and grooves.As may be expected, the beams provide very little, if any, support in avertical direction. The columns so constructed are consideredindependent because, unlike conventionally constructed masonry or stonewalls, the joints between adjacent blocks are in alignment with eachother rather than being offset as in a running bond. This enables thecolumns of blocks to move up and down relative to each other, withoutappreciably altering the inherent continuity of a wall structure. Aswill be appreciated, the rigidity of the blocks provides enough supportto prevent a column from failing in the vertical direction. When a morerobust wall structure is desired, blocks that have appropriatelyconfigured apertures and rearwardly facing slots may be stacked in arunning bond arrangement and strengthened and linked together by supportbeams. Although the beams can be fabricated form a variety of materialssuch as metals and plastics, extruded aluminum, nylon, and polyvinylchloride (PVC) are preferred.

It will be appreciated that the use of the lateral support beams alsoeliminates and/or substantially reduces the need for mortar to stabilizeand unify the blocks. This wall structure system is advantageous overtraditional brick and mortar walls for obvious reasons. First, fewermaterials are required to build a wall. Second, the materials are easierto handle and manipulate, and no special tools or skills are required.Third, a wall can be constructed under conditions that would not bepossible using traditional brick and mortar construction and a personneed not be concerned about time constraints imposed by drying mortar.Fourth, the joints formed between adjacent blocks allow the wall toappear monolithic or seamless at a surprisingly close distance.Moreover, by providing blocks that have had their marginal areasmodified, it is also possible to create walls that have the appearanceof conventional block and mortar construction. Fifth, the block wallsystem can be constructed on a variety of surfaces, including sand,gravel, dirt, or building elements such as H-beams, flooring, baseblocks, etc. It is not necessary to pour a foundation.

The lateral support beams also allow the blocks to be substantiallythinner than conventional masonry blocks. These thin, lightweight blocksare not only easier to handle and ship, but require less material andtime to fabricate. The blocks are generally about 1 to 4 inches (2.5-10cm.) thick, about 6 to 12 inches (15-30 cm.) in height and about 6 to 24inches (15-60 cm.) in width, and preferably have a thickness on theorder of around 2½ inches (6.0 cm.). As one may appreciate, thecombination of the thin blocks and the support beams facilitatesconstruction of masonry wall structures in locations and configurationsthat were heretofore not possible using thin blocks alone. The resultingwall structure of this system is surprisingly strong and it may even beused to provide support to an elevated structure. When a wall structureis installed about an elevated structure, such as a portable home, theelevated structure may be lowered onto the blocks of the wall.Alternatively, the block wall system may serve as a skirt, whichimproves the aesthetics of the structure and keeps animals, litter,snow, etc. from intruding or being otherwise introduced beneath thestructure. Or, the block wall system may be used with existingstructures such as elevated decks and retaining walls. With theseembodiments, it is not necessary that the blocks make actual contactwith the structure.

The block wall system also allows the wall to be easily disassembled andreassembled. This not only gives flexibility during initialconstruction, but also allows later renovations to be made quickly andinexpensively. For instance, it may be desirable or required to ventelevated structures having skirting walls, to prevent the buildup ofmoisture or condensation between the ground and the elevated structure.Such vents can be easily installed into an existing wall, especially ifthey are of similar dimensions and configurations as the blocks. Theblocks of a given column are simply removed and reinstalled, replacingone of the blocks with the vent. Other auxiliary items, such as anaccess door or lights, could be installed in a similar manner.

The wall block system of the present invention is not confined to linearstructures. As will be appreciated, the system also allows walls tointersect to form angled or closed structures. In one embodiment, twointersecting walls are simply aligned to form a butt joint and fastenerssuch as pegs, or screws, and plastic inserts are used to fasten one wallto the other. Alternatively, construction mastic, or a similar type ofadhesive, may be applied instead of or in combination with theabovementioned fasteners. In another embodiment, blocks are preformed asangled intersecting wall units that have been provided with outwardlyopening, vertically oriented side grooves configured to receive portionsof support beams, which may be further linked to other wall blocks asdescribed above. As will be appreciated, such blocks may be combinedtogether to form hollow columnar structures, or may be used to clad anexisting structure such as a support post. Again, ease of installationis greatly improved by the block wall system of the present invention.

Another embodiment of the wall structure uses a differently configuredbracket than the aforementioned u-shaped bracket. It, too, is used tooperatively connect the wall structure to a support. The bracket of thisembodiment, however, attaches in a slightly different manner than theu-shaped bracket. Instead of straddling the upper portion of a top-mostblock as with the u-shaped bracket of the aforementioned embodiment,this bracket has one end that is configured to be positioned withinspace defined by opposing vertical grooves of adjacent blocks. That is,the bracket is designed to be installed at or near the sides of acolumn. The other end of the bracket is configured to be attached at ornear the bottom of a structure. An advantage with this bracket it thatit is able to provide support for the wall structure in two directions,while allowing movement of wall components relative thereto in a thirddirection. As will be appreciated, this bracket may be easily installedand removed without the need for special training or tools. Preferably,the bracket of this embodiment is L-shaped, although it is envisionedthat other shapes are possible. For example, the bracket may be linear,or it may be linear and have an axial twist in it. Or, thestructure-engaging portion may be provided with a u-shape or even itsown integral fastener.

An assembly of blocks may be operatively connected to a support usingyet another embodiment of the wall skirting system. With thisembodiment, the support beam is configured to be movably coupled to oneor more brackets that, in turn, may be attached to the support. Thisallows the beam to move relative to the bracket(s) without sacrificingthe strength of the assembled blocks, and also allows the beams to beconnected to the structure at different locations along its length. Forexample, at the top, at the bottom, or anywhere in between. As will beunderstood, in order for the support beam and bracket to operate in sucha constrained manner the bracket(s) need to be configured so that theyare able to slidingly retain the beam. Thus, differently configuredbeams may require specially configured brackets.

In another embodiment of the block wall system, blocks are operativelyconnected to a structure with one or more brackets, which are configuredto be able to engage the side grooves of adjacent blocks, and which maybe directly attached to the structure. As will be appreciated, thebrackets of this embodiment will permit the blocks to move relativethereto, but not to the degree that is available with the aforementionedsupport beam and bracket combination. As with the aforementioned supportbeams, the brackets can be fabricated form a variety of materials suchas metals and plastics. However, steel, extruded aluminum, nylon, andpolyvinyl chloride (PVC) are preferred.

It will be appreciated that wall structures other than linear structuresare possible. For example, support beams and blocks may be used toconstruct circular, or sinuous structures by providing curved blocks orblocks with one curved viewable surface (when viewed cross-sectionallyfrom a point above the top surface of the block) that are operativelyconnected to support beams that are similarly arranged. Alternatively, awall structure may be constructed in a zigzag or erose form with thesupport beams collaterally arranged relative to each other in a zigzagmanner. To reduce vertical gaps between forwardly facing viewablesurfaces of adjacent blocks in such a wall structure, it would be amatter of providing support beams with ribs that are angled with respectto the web and mitering or beveling the opposing sides of the blocks, orusing a combination of both angling and mitering the ribs and sides,respectively. A similarly configured wall may also be constructed usingsupport beams arranged in a coplanar or staggered fashion relative toeach other and blocks having a predetermined, angular viewable surface(when viewed cross-sectionally from a point above the top surface of theblocks). For example, a “V”, “L”, or a “W”. Such blocks may haveparallel front and rear faces, if desired. With such a construction,neither the support beams nor the opposing fingers need to be modified.In a related construction, it is envisioned that blocks be constructedhaving angles of ninety degrees so that they may be used as inner orouter corners. With such blocks, the opposing sides and their fingerswould be perpendicular to each other.

In one method of constructing a freestanding, low wall structure of thepresent invention, a person would prepare or otherwise select anappropriate location in which to construct a wall. The constructionwould begin by placing a first block having opposing side grooves in adesired position and orientation. Then, a second, similar block would beplaced directly on top of the first block so that the opposing sidegrooves of the first and second blocks are in vertical alignment witheach other and the first and second blocks form a column. Next, thefirst and second blocks would be operatively connected to each otheralong their respective sides by inserting at least one rib of first andsecond support beams into the aligned grooves of the respective sides ofthe first and second blocks and seating them securely. A second columncomprising similarly configured third and a fourth blocks may now beconstructed. The operation is much the same, except now the third blockis positioned so that one of its sides is adjacent to one of the sidesof the first block and its groove engages at least one other rib of oneof the already positioned support beams. The fourth block is thenpositioned on top of the third block in a similar manner. That is, thefourth block is positioned so that one of its sides is adjacent to oneof the sides of the second block and its groove engages at least oneother rib of one of the already positioned support beam. After thesecond column is erected, the third and fourth blocks would beoperatively connected to each other along their respective free side byinserting at least one rib of a third support beam into their alignedvertical groove of the respective sides of the first and second blocksand seating them securely. And so on.

Another, alternative method of constructing a wall structure of thepresent invention according to the present invention would be asfollows. A person would prepare or otherwise select an appropriatesubstructure on which to construct a wall structure. The constructionwould begin by operatively connecting a first elongated support beam tothe substructure. Then using the first support beam as a reference, aseries of additional support beams would be operatively connected to thesubstructure, with all of the support beams in vertical and collateralalignment, and with the distance between adjacent support beamssufficient to enable the ribs of adjacent beams to engage opposing sidegrooves of a block. Once the dimensions of the wall structure have beenestablished, the blocks with opposing side grooves may be positioned bysliding the blocks along the length of and between adjacent supportbeams. This may be done course by course, column by column, or in amixture of both columns and courses, as desired.

In a variation of the aforementioned methods of construction, a personwould begin by operatively connecting a first elongated support beam tothe substructure in a vertical orientation. Then a first block havingopposing side grooves would be placed in a desired position andorientation against the first elongate support beam so that at least oneof the ribs of the first beam is seated within one of the side groovesof the block. Then, a second, similar block would be placed directly ontop of the first block so that the at least one rib of the first beam isalso seated within one of the side grooves of the second block so thatthe opposing side grooves of the first and second blocks are in verticalalignment with each other and the first and second blocks form a column.Next, the first and second blocks are operatively connected to eachother along their other respective sides by aligning the grooves of therespective sides of the first and second blocks, and inserting at leastone rib of a second support beam into the aligned grooves and seating itsecurely therein. After the second support beam is seated, it isattached to the substructure. A second column comprising similarlyconfigured third and a fourth blocks may now be constructed. Theoperation is the same, with the third block positioned so that one ofits sides is adjacent to one of the sides of the first block and itsgroove engages another rib of the already positioned second supportbeam. The fourth block is then positioned on top of the third block in asimilar manner. That is, the fourth block is positioned so that one ofits sides is adjacent to one of the sides of the second block and itsgroove engages another rib of the already positioned second supportbeam. After the second column is erected, the third and fourth blockswould be operatively connected to each other along their respective freeside by aligning the grooves of the respective sides of the third andfourth blocks, and inserting at least one rib of a third support beaminto the aligned grooves and seating it securely therein. After thethird support beam is seated, it is attached to the substructure. And soon.

Additional advantages and features of the invention will be set forth inpart in the description which follows, and in part, will become apparentto those skilled in the art upon examination of the following or may belearned by practice of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial, perspective view of two embodiments of the blockwall system, with one preferred embodiment of blocks arranged below anelevated first (upper level) deck structure and another embodiment ofblocks arranged about the perimeter of an adjacent, elevated second(lower level) deck structure;

FIG. 2 is a partial, exploded, perspective view of the block arrangementbelow the elevated first (upper level) deck structure of FIG. 1;

FIG. 2 a is a top plan view of the block arrangement of FIG. 1, takengenerally along lines 2 a-2 a;

FIG. 3 is a side elevational, cross-sectional view of the blockarrangement about the perimeter of the elevated second (lower level)deck structure of FIG. 1 taken generally along lines 3-3;

FIG. 3 a is a partial, side elevational, cross-sectional view of analternative support for the block arrangement of FIG. 3;

FIG. 4 is a perspective view of an elevated structure skirted with anembodiment of the blocks of the present invention arranged in a wallstructure;

FIG. 5 is a side elevational view the wall structure of FIG. 4 takengenerally along lines 5-5;

FIG. 6 is a partial, perspective view of an embodiment of blocksarranged to provide a facia wall for a retaining wall;

FIG. 6 a is a partial, side elevational, cross-sectional view of theblock arrangement of FIG. 6 taken generally along lines 6 a-6 a;

FIG. 7 is a perspective view of another embodiment of a block of thepresent invention;

FIG. 7 a is a perspective view of another embodiment of a block of thepresent invention;

FIG. 7 b is a bottom plan view of the block of FIG. 7 a;

FIG. 8 is a partial, cross-sectional, plan view of an embodiment of acorner construction of a wall structure of the present invention;

FIG. 9 is a perspective view of another embodiment of a block of thepresent invention;

FIG. 10 is a bottom plan view of the block of FIG. 9;

FIG. 11 is a partial, perspective view of an embodiment of a supportbeam of the present invention;

FIG. 11 a is a partial, perspective view of an alternative embodiment ofa support beam of the present invention;

FIG. 12 is a partial, perspective view of an alternative embodiment of asupport beam;

FIG. 13 is a partial, perspective view of an alternative embodiment of asupport beam;

FIG. 14 is a plan view of an alternative embodiment of a blockengagement portion of a vertical support beam similar to that of FIG. 11a, with the remainder of the support beam shown in phantom;

FIG. 15 is a plan view of an alternative embodiment of a blockengagement portion of a support beam similar to that of FIG. 11 a, withthe remainder of the support beam shown in phantom;

FIG. 16 is a partial, perspective view of an embodiment of a supportbeam of the present invention;

FIG. 17 is a partial, perspective view of another embodiment of asupport beam in conjunction with a bracket, with the bracket configuredto be attached to a sub structure;

FIG. 18 is a partial, perspective view of another embodiment of asupport beam in conjunction with another embodiment of a bracket, withthe bracket configured to be attached to a sub structure;

FIG. 19 is a partial, perspective view of another embodiment of asupport beam in conjunction with another embodiment of a bracket withthe bracket configured to be attached to a substructure;

FIG. 20 is a partial, perspective view of an embodiment of a supportbeam having an integrally formed aperture and an integrally formedbracket, with the support beam able to be used with the support beam ofFIG. 19 to construct/form a double sided wall structure;

FIG. 21 a partial, perspective view of another embodiment of a supportbeam;

FIG. 22 is a partial, top plan view, taken generally along lines 22-22of FIG. 4, of showing adjacent blocks of the present invention inconjunction with a support beam;

FIG. 23 is a partial, top plan view of the two blocks abutted with asupport beam of FIG. 22, but with the support beam arranged in analternative configuration;

FIG. 23 a is a partial, top plan view of the blocks of FIG. 23 as theymay be assembled into a wall structure, or as a wall structure isdisassembled;

FIG. 24 is a partial, top plan view of two blocks, a support beam, and asupport bracket that have been assembled into a wall structure;

FIG. 24 a is a partial, top plan view of a portion of the blocks,support beam, and bracket of FIG. 24, as they may be assembled into awall structure, or as a wall structure is disassembled;

FIG. 25 is a partial, top plan view of two blocks of the presentinvention in conjunction with an alternative embodiment of a supportbeam;

FIG. 26 is a partial, top plan view of two blocks of the presentinvention in conjunction with another alternative embodiment of asupport beam;

FIG. 27 is a partial, top plan view of the support beams shown in FIGS.12 and 13 in conjunction with blocks of the present invention;

FIG. 28 is a partial, top plan view of two blocks of FIG. 7 a that areoperatively connected to the support beam of FIG. 11 a;

FIG. 29 is a partial, top plan view of the support beam of FIG. 16 as itmay be used to operatively connect blocks of the present invention to asubstructure;

FIG. 30 is a perspective view of a wall structure construction usinganother preferred embodiment of support beams and blocks of the presentinvention;

FIG. 31 is a partial, top plan view of the support beam and bracket ofFIG. 17 as they may be used to operatively connect blocks to asubstructure;

FIG. 32 is a partial, top plan view of the support beam and bracket ofFIG. 18 as they may be used to operatively connect blocks to asubstructure;

FIG. 33 is a partial, top plan view of the support beam and bracket ofFIG. 19 as they may be used to operatively connect blocks to asubstructure;

FIG. 34 is a partial, top plan view of an alternative embodiment of thesupport beam of FIG. 21 as it may be used to operatively connect blocksto a substructure;

FIG. 35 is a partial, top plan view of the support beam of FIG. 21 as itmay be used to operatively connect blocks to a substructure;

FIG. 36 is a partial, top plan view of the support beam of FIG. 20 andthe support beam of FIG. 19 as they may be used to operatively connectdifferently sized blocks together in a dual-sided wall structure;

FIG. 37 is a partial, top plan view of the blocks of FIG. 7 inconjunction with another embodiment of a support beam, with the supportbeam operatively connecting the blocks to an existing structure;

FIG. 37 a is a partial, top plan view of the blocks of FIG. 7 inconjunction with another alternative embodiment of a support beam withthe support beam operatively connecting the blocks to an existingstructure;

FIG. 37 b is a partial, top plan view of blocks of FIG. 7 in conjunctionwith another alternative embodiment of a support beam with the supportbeam operatively connecting the blocks to an existing structure;

FIG. 38 is a partial, top plan view of a free standing dual wallstructure wherein the respective walls of the wall structure areconnected to each other in a spaced relation by an alternativeembodiment of a support beam;

FIG. 39 is a partial, top plan view of blocks of FIG. 7 in conjunctionwith an alternative embodiment of the support beam of FIG. 20, whereinthe aperture is configured to received a post;

FIG. 40 is a partial, perspective view of an embodiment of a wallstructure of the present invention and a preferred attachment bracket;

FIG. 41 is a perspective view of the attachment bracket of FIG. 40;

FIG. 42 is a side elevational view of the bracket of FIG. 41 attached toa lower surface of a structure, and as it may be attached to an uppersurface of the structure (shown in phantom);

FIG. 43 is a perspective view if the attachment bracket of FIG. 41 as itmay be used in conjunction with the support beam of FIG. 11;

FIG. 44 is an exploded, perspective view of an attachment bracket andthe support beam of FIG. 11 a;

FIG. 45 is a rear perspective view of the attachment bracket and supportbeam of FIG. 44 after they have been operatively connected to eachother;

FIG. 46 is a perspective view of an alternative embodiment of anattachment bracket suitable for use with a support beam as depicted inFIG. 11 a;

FIG. 47 is a plan view of the attachment bracket of FIG. 46 as it may beoperatively connected to a support beam as depicted in FIG. 11 a;

FIG. 48 is a perspective view of an alternative embodiment of anattachment bracket having an arm that is rotatably connected thereto,and which is in a first position;

FIG. 49 is a perspective view of the attachment bracket of FIG. 48 inwhich the arm has been rotated to a second position;

FIG. 50 is a perspective view of an embodiment of an attachment bracket;

FIG. 51 is a partial, perspective view of a wall structure in whichblocks of the present invention are operatively connected to asubstructure by the vertically oriented support beams and brackets ofFIGS. 2 and 2 a;

FIG. 52 is another partial perspective view of a wall structure in whichblocks of the present invention are operatively connected to asubstructure by horizontally oriented support beams and brackets ofFIGS. 2 and 2 a;

FIG. 53 is a side elevation view of a block wall structure that isoperatively connected to a structure;

FIG. 54 is an edge view of a sealing element that is used in theconstruction of the wall structure of FIG. 53;

FIG. 55 is a perspective view of the sealing element of FIG. 54;

FIG. 56 is an enlarged view of a portion of FIG. 53, which depicts thesealing element of FIGS. 54 and 55 as it resides between structuralelements;

FIG. 57 is a perspective view of an alternative embodiment of anattachment bracket for use in conjunction with blocks of the presentinvention;

FIG. 58 is a perspective view of an alternative embodiment of anattachment bracket for use in conjunction with blocks of the presentinvention;

FIG. 59 is a perspective view of an alternative embodiment of anattachment bracket for use in conjunction with blocks of the presentinvention; and,

FIG. 60 is a plan view of the brackets of FIGS. 57 and 59 operativelyconnecting blocks of the present invention to a substructure.

DETAILED DESCRIPTION

FIG. 1 illustrates several embodiments of the wall block system ofpresent invention, as practiced with an elevated first (upper level)deck d1 and an adjacent, elevated second (lower level) deck structured2. The first embodiment is an elevated upper level deck structure d1,which is supported by a plurality of vertical posts that have beenprovided with an external sheathing of blocks that are operativelyconnected to the posts by support beams and brackets.

As depicted, the blocks used to sheath the post are angled blocks, suchas depicted in FIGS. 2 and 2 a. The blocks, which are provided withgrooves at their side edges, are configured to be operatively connectedto a post by one or more support beams 716, which will be discussedlater in greater detail. As depicted, the support beams may be directlyattached to the post. Alternatively, the blocks may also be operativelyconnected to the post by a support beam and a bracket 354 (see, forexample, FIG. 2 a, which will be discussed later in greater detail), orby brackets alone (see FIGS. 57, 58, 59 and 60). While it will beunderstood that a post sheathing will be relatively robust, it may bedesirable to create a more permanent structure. This can be achieved,for example, by providing the horizontal and/or vertical edge surfacesof the blocks with a suitable adhesive 58 (vertical edge surfaces shownin phantom). Alternatively, the blocks may be secured by one or morecircumferential bands of material (not shown).

Referring again to FIGS. 1, 2 and 2 a, it will be apparent that gaps mayexist between the blocks and the post, and that moisture and debris mayinfiltrate the gaps from above, and/or between the joints betweenadjacent blocks. As will be understood, such infiltration may besubstantially reduced by providing the sheathed post with cap stones,flashing gaskets or other construction elements that serve toeffectively close the gaps from above. Infiltration reduction may alsobe achieved by providing the horizontal and vertical edge surfaces withcaulking material.

The second embodiment of the block wall system of FIG. 1 depicts anotherapplication of the present invention, where blocks are used to skirt anelevated, lower level, second deck structure d2. In this application,the wall structure comprises several block embodiments. Starting fromthe left corner, the upper and lowermost courses comprise blocks thatare similar to the corner blocks of FIGS. 2 and 2 a. The middle course,while it could comprise a block of FIGS. 2 and 2 a, is constructed usingtwo linear blocks that are connected to each other by fastening elementsuch as pins and/or adhesive material (see, for example, FIG. 8).Continuing towards the right, the next block embodiments, which will bediscussed later in greater detail, are generally linear and as will bediscussed later, configured to be operatively connected to the deckframe. Continuing on to the right corner, the arrangement of the blocksis similar to the arrangement of the blocks depicted at the left corner.The right corner differs, however, in that the corners formed by theblocks are not ninety degrees. Instead, the corner formed by theintersection of two walls is obtuse.

As will be discussed later in greater detail, the skirting structureblocks may be operatively connected to the deck frame in a mannersimilar to the previously discussed post sheathing. That is, through theuse of support beams, support beams and bracket, or brackets. The wallstructure depicted in FIG. 5 uses a support beam that is attacheddirectly to the deck frame. As will be discussed later, the support beamserves to maintain and align a plurality of blocks. As depicted, theblocks of FIG. 5 are supported by a longitudinal L-shaped support barthat is also attached to the deck frame. With this operative connection,the blocks are not subject to external forces such as frost heave, andare generally static.

In the partial depiction wall structure of FIG. 5 a, the support beam isindirectly connected to the deck frame by one or more brackets. In thisinstance, the beam and bracket combination is similar to the beam andbracket combination of FIG. 2 a. This combination allows the beam (andblocks), which rest on a footing, to move in response to external forcessuch as frost heave. In this regard, the operative connection can beconsidered dynamic.

FIG. 3 is a perspective view of an elevated structure “S” skirted with awall system 10 of the present invention. Generally, the wall structure10 comprises of a plurality of blocks 12 forming columns 14 (see also,FIG. 4) partially spaced apart and held in place by vertically oriented,lateral support beams (see, for example, FIGS. 5, 11, 22, and 23).Downward opening brackets 18 (see FIGS. 5 and 22) that are attached tothe bottom of the structure “S” being skirted, are configured to engagedthe top block 12 of selected columns 14 to help prevent the wallstructure 10 from tipping rearwardly or forwardly. As used herein, theterm “forward” means away from the center of the elevated structure “S”and the term “rearward” means toward the center of the elevatedstructure “S”.

FIGS. 4 and 7 show an arrangement of blocks 12 that form a plurality ofcolumns 14. Referring particularly to FIG. 7, each block 12 is generallypanel-shaped and includes a front face 20, a rear face 22, a top surface24, a bottom surface 26 and pairs of side surfaces 28 a, 29 a and 28 b,29 b, respectively. The side surface pairs 28 a, 29 a and 28 b, 29 b,respectively, are preferably somewhat perpendicular to the rear face 22and/or the front face 20. Side surface 28 a is spaced from side surface28 b by a distance (taken along a “x” direction in a three-dimensionalcoordinate system relative to the blocks 12) to define a width 33 of theblock 12. Additionally, each pair of side surfaces 28 a and 29 a, 28 band 29 b, include a substantially vertical groove 34 therebetween, whichis configured to receive a portion of a lateral support beam 16 (See,for example, FIG. 11).

Note that while the top and bottom surfaces 24, 26 of adjacent blocks 12are configured to contact each other without thick layers of mortar orbinding material therebetween, it is envisioned that the use of thinlayers of intermediate materials, which may serve to strengthen and/orprovide resistance to moisture may be practiced without departing fromthe spirit and scope of the invention. Moreover, it will be apparentthat thin or no intermediate layers will minimize the spacing betweenblocks and allow the marginal areas 23 c, 23 d of adjacent blocks 12 tocombine and simulate horizontally oriented splitting recesses.

As will be understood, the brackets 18 (see FIGS. 4 and 22) preventrearward or forward movement of the column 14 and also work inconjunction with the beam 16 to prevent columns 14 not in direct contactwith the bracket 18 from tipping over rearwardly or forwardly. It isenvisioned that the beams 16 may be directly attached to the wallstructure 10 (similar to FIG. 29) or alternatively, the bracket 18 maybe solely responsible for preventing the wall structure 10 from tippingover. While it will be understood that the bracket 18 can be of anysuitable material, synthetic, more preferably poly-vinyl chloride (PVC)or other durable plastic is preferred.

The bracket 18 comprises a front wall 44, a rear wall 46 spaced apartfrom front wall 44 and a top wall 48 joining the front wall 44 to therear wall 46 in a generally inverted “U”-shape. The front wall 44 andthe rear wall 46 define an opening 50, which is configured and arrangedto receive an uppermost portion of the top block 12 of a column 14. Inpractice, the bracket 18 is attached at or near the underside of astructure “S” to be skirted so that the opening 50 can receive the upperportion of the top block 12 of a column 14. Preferably, the bracket 18is positioned such that it may straddle the central region of anuppermost block 12. It may be desired to make rear wall 46 of a greatervertical dimension than the front wall 44 to provide additional support.It may also be desired to provide a bracket 18 with a rear wall 46,width that extends in a lateral direction further than the front wall 44width. Furthermore, it is envisioned that the bracket 18 can be formedinto a variety of lengths. For instance, the bracket 18 can be as shortas one inch or as long as the entire skirted structure “S”.

While the top wall 48 of the bracket 18 is depicted in FIG. 4 as beingin contact with the top surface 24 of the uppermost block 12 of thecolumn 14, it should be understood that this need not always be thecase. In situations where the wall structure 10 is not a load bearingwall, or where the terrain shifts or changes due to climate, settling,animals, roots, etc., it may be desirable to provide a gap between thetop wall 48 and the top surface of the wall structure 10. Thus,individual columns 14 will be able to move vertically in smallincrements without destroying the integrity of the wall structure 10 orthe skirted structure (not shown). In that regard, it should beappreciated that the beams 16 slidingly grip portions of the blocks 12.That is to say, the beams 16 do not grip the blocks 12 with so muchforce as to preclude relative movement of the blocks 12 therealong in alongitudinal direction.

FIGS. 6 and 6 a show an embodiment of another application of the presentinvention, where blocks are used to provide a facia wall in front of anexisting retaining wall. The facia wall is formed using support beamsand brackets similar to the beams and brackets depicted in FIGS. 2 and 2a. That is, the support beam 716, as shown, comprises an elongated spineor web 718 and plurality of ribs 720 and 722, 724 and 726, which arearranged in a substantially coplanar and collateral relation so that thefirst pair of ribs 720, 722, which are substantially coplanar and extendaway from each other. The first pair of ribs 720, 722 are designed toengage the grooves of one or more blocks of a structure (see, forexample, FIG. 6 a).

In addition, the web 718 also includes a second pair of ribs 724, 726,which are also substantially coplanar and which extend away from eachother. Note that the pairs of ribs 724 and 726 are in substantiallycollateral or parallel relation with respect to each other and arespaced apart from each other by a distance defined by the web 718. Asbetter shown in FIGS. 51 and 52, the support beam 716 also includes apair of pair of leg structures 730 having leg portions 732 a, 732 b thatthey extend rearwardly away from ribs 724, 726 and which form agenerally U-shaped channel therewith. One of the leg portions 732 bincludes a foot 734. that extends laterally away from the leg portion732 b and is generally parallel with ribs 724, 726. As with theembodiment of FIGS. 2 and 2 a, the foot may be connected directly orindirectly to a support structure. However, as depicted, the beams ofFIGS. 6 and 6 a are operatively connected to a structure by a pluralityof brackets 354, which are attached to blocks of the retaining wall.With such an arrangement the beams, which are slidingly constrained bythe brackets, permit blocks to move without destroying the integrity ofthe structure.

The brackets 354 used to operatively connect the beams 718 to theretaining wall blocks generally comprise a structure engaging portion, aweb, and a support beam engaging portion. As shown in FIG. 50, thestructure engaging portion 356 of bracket 354 comprises a single orfirst member 357 that is provided with an aperture 360, which is used tofacilitate attachment to the retaining wall with fastening elements suchas nails, threaded fasteners, or anchor bolts. It will be appreciated,however, that an aperture or apertures need not be present in order toattach the bracket to a structure. The fastening element(s) may bedriven through the first member, if desired. Additionally, it will alsobe appreciated that attachment may also be achieved with suitableadhesives, in lieu of, or in addition to, fastening elements. Thesupport beam engaging portion 358 comprises a web 362 and a pair of legs364, 366, which are angled with respect to the web to form a generally“L”-shape. The web 362 includes an aperture 368 that is accessiblethrough a slot 370 defined by edges 372 and 374 of legs 366 and 364,respectively. The aperture 368 and slot 370 are configured to slidinglyreceive a leg portion 732 b and foot 734 of a support beam (see also,FIGS. 50, 51 and 52).

Attention is now directed to the individual components of a wallstructure 10. FIG. 7 depicts a preferred embodiment of a block 12. Itcan be seen that the block 12 is generally panel-shaped and includes afront face 20, a rear face 22, a top surface 24, a bottom surface 26 andpairs of side surfaces 28 a, 29 a and 28 b, 29 b, respectively. Theblock 12 is preferably made of a composite masonry material in adry-cast molding operation. Though the general shape of the blocks 12 ismore important than the material used in order to practice the presentinvention, composite masonry material provides the most desirablecombination of strength, appearance, economy, and ease of manufacturing.It is envisioned, however, that other materials can be used, such asconcrete, fiberglass, ceramics, hard plastics, dense foam, or even wood.

The front face 20 is spaced from the rear face 22 by a predetermineddistance herein defining the thickness or depth 30 (generally about 1 to4 inches (2.5 to 10.0 cm)) of the block 12. As shown in FIG. 7, thefront face 20 is formed to have a roughened or rustic surface. Suchsurfaces commonly result during block fabrication, where a mold is castand the casting is later split or fractured into two blocks along apredetermined plane, with the plane of separation between the two blocksdefining a pair of opposing front faces. Splitting is not necessary tocarry out the spirit of the invention, however, and the block 12 may beformed by other known methods. Moreover, the front face 20 can bedressed, modified, or otherwise worked in any desired manner.

A vertically oriented splitting recess 21 may be provided on the frontface 20 of the block 12 to enable the block 12 to be fashioned intopredetermined shapes. In FIG. 7, the splitting recess 21 is depicted asbisecting the block 12. However, it is understood that the splittingrecess can be located and oriented elsewhere on the block. That is, thesplitting recess can be off-center, horizontal, diagonal, etc. Moreover,it is also understood that the block can be provided with more than onesplitting recess, if desired.

The front face 20 includes marginal areas 23 a, 23 b, 23 c, and 23 d. Asmay be expected, the number of marginal areas corresponds to the numberof edges of the front face 20. These marginal areas may be worked ormodified, if desired, to produce different visual effects. Here, thedesired effect is for the marginal areas 23 a, 23 b, 23 c, and 23 d tosimulate splitting recesses 21. Thus, the marginal areas 23 a, 23 b, 23c, and 23 d are formed so that when blocks 12 are positioned in contactwith each other in a wall structure 10, the cross-sectional profiles oftheir marginal areas 23 a, 23 b, 23 c, and 23 d, when combined, simulatesplitting recesses 21. As depicted the splitting recesses 21 have across-sectional profile that is somewhat circular, and the marginalareas 23 a, 23 b, 23 c, and 23 d have cross-sectional areas that arefluted or arced. As can be appreciated, the splitting recesses 21 andmarginal areas 23 a, 23 b, 23 c, and 23 d may be configured with othercross-sectional profiles, if desired. For example, a “V”-shapedcross-sectional profile.

As mentioned above, tight or thin joints 31 (See FIG. 3) betweenadjacent blocks 12 enables a wall structure to appear monolithic orseamless. This feature may be used in combination with splittingrecesses 21 and marginal areas 23 a-d of the blocks 12 to createdifferent visual effects. For example, it is envisioned that a wallstructure may simulate running bonds by having the blocks of each columnalternate between a block with no splitting recess and worked marginalareas and a block having a splitting recess and worked horizontalmarginal areas (see, for example, FIG. 40). Or, it is envisioned thatthe splitting recesses and marginal areas be selected to enable the wallstructure to simulate an ashlar block wall (not shown).

Referring again to FIG. 7, the top surface 24 is spaced from the bottomsurface 26 by a distance (taken along a “y” direction in athree-dimensional coordinate system relative to the block 12) to definethe height 32 (about 6 to 12 inches (15 to 30 cm)) of the block 12. Whenblocks 12 are arranged vertically to form a column 14 (see FIG. 4), thebottom surface 26 of any block 12 other than the bottom block of acolumn 14 (not shown) rests on the top surface 24 of the blocktherebelow. It is therefore preferred that the top surface 24 and thebottom surface 26 be configured to facilitate a stacking relationshipbetween two blocks 12. A stacking relationship is most easily achievedby making the top and bottom surfaces 24, 26 substantially collateral,planar, and relatively perpendicular to the rear face 22 and/or thefront face 20, as best shown in FIGS. 4 and 5. Alternatively, it isenvisioned that top and bottom surfaces 24, 26 may be complementarilyshaped, and not perpendicular to the rear face and/or the front face,but which permit upper and lower blocks to be stacked in a verticalrelationship (not shown). For example, the surfaces could be non-planarand/or irregular. Alternatively, the surfaces can have compound curvesor even interlocking segments (not shown).

The side surface pairs 28 a, 29 a and 28 b, 29 b, respectively, arepreferably somewhat perpendicular to the rear face 22 and/or the frontface 20. Side surface 28 a is spaced from side surface 28 b by adistance (taken along a “x” direction in a three-dimensional coordinatesystem relative to a block 12) to define the width 33 (6 to 24 inches(15 to 60 cm)) of block 12. Additionally, each pair of side surfaces 28a and 29 a, 28 b and 29 b, include a substantially vertical groove 34therebetween that is configured to receive a portion of a lateralsupport beam 16 (see, for example, FIG. 11). While a pair of sidegrooves for each block is preferred, it is envisioned that one sidesurface be provided with a groove and the other side surface have atongue configured to mate with the groove, thereby obviating the needfor beams 16. However, in order to maintain the vertically independentcharacteristics of columns 14, the use of beams 16 is preferred.

Referring now to FIGS. 7 a and 7 b, another embodiment of the block ofthe present invention is depicted. The block 112 is generallypanel-shaped and includes a front face 120, a rear face 122, a topsurface 124, a bottom surface 126 and pairs of side surfaces 128 a, 129a, and 128 b, 129 b, respectively.

The front face 120 is spaced from the rear face 122 by a predetermineddistance defining the thickness or depth 130 (generally about 1 to 4inches (2.5 to 10.0 cm)) of the block 112. As shown in FIG. 7 a, thefront face 120 is formed to having a roughened or weathered surface.However, it is understood that the front face 120 could, be dressed,modified, or otherwise worked in any desired manner.

Vertically oriented splitting recesses may be provided on the front faceof the block to enable the block to be fashioned into predeterminedshapes. Here, the splitting recesses 121 are depicted as quartering theblock 112 and forming front face segments 125 a, 125 b, 125 c, and 125d. However, it is understood that the splitting recesses 121 may belocated and oriented elsewhere on the block 112. That is, the splittingrecesses 121 could be off center, horizontal, diagonal, etc. Moreover,it is also understood that a block splitting recesses 121 may beomitted, if desired.

The front face 120 includes marginal areas 123 a, 123 b, 123 c, and 123d. As may be expected, the number of marginal areas corresponds to thenumber of edges of the front face 120. The marginal areas 123 a-d may beworked or modified, if desired, to produce different visual effects. InFIG. 7 a, the desired visual effect is for the marginal areas tosimulate splitting recesses. Thus, the marginal areas 123 a-d are formedso that when blocks 112 are positioned in contact with each other in awall structure 10 (See FIG. 3, for example), the cross-sectionalprofiles of their marginal areas 123 a-d, when combined, simulatesplitting recesses at the joints formed by the block. As depicted, thesplitting recesses 121 have a cross-sectional profile that is somewhatcircular, and the marginal areas 123 a-d have cross-sectional areas thatare fluted or arced. As can be appreciated, the splitting recesses andmarginal areas 123 a-d may be configured with other cross-sectionalprofiles, if desired. For example, a “V”-shaped cross-sectional profile.

Referring again to FIG. 7 a, the top surface 124 is spaced from thebottom surface 126 by a distance (taken along a “y” direction in athree-dimensional coordinate system relative to the block 112) to definethe height 132 (about 6 to 12 inches (15 to 30 cm)) of the block 112.When the blocks 112 are arranged vertically to form a column 14 (see,for example, FIGS. 4 and 5), the bottom surface 126 (not shown) of anyblock 112 other than the bottom block of a column 14 (See FIG. 5) restson the top surface 124 of the block 112 therebelow. It is thereforepreferred that the top surface 124 and the bottom surface 126 beconfigured to facilitate a stacking relationship between two blocks 112.A stacking relationship is most easily achieved by making the top andbottom surfaces 124, 126 substantially collateral, planar and relativelyperpendicular to the rear face 122 and/or the front face 120, as shownin FIGS. 4 and 5. Alternatively, it is envisioned that the top surface124 and the bottom surface 126 (see FIG. 7 b) may be complementarilyshaped, and not perpendicular to the rear face 122 and/or the front face120, as long as the upper and lower blocks 112 can be stacked in avertical relationship. For example, the surfaces 124, 126 (not shown)can be non-planar and/or irregular. Or, the surfaces 124, 126 (notshown) can have compound curves or interlocking segments (not shown).

Referring to FIG. 7 b, the side surface pairs 128 a, 129 a and 128 b,129 b, respectively, are preferably somewhat perpendicular to the rearface 122 and/or the front face 120. The side surface 128 a is spacedfrom the side surface 128 b by a distance (taken along the “x” directionin a three-dimensional coordinate system relative to the block 112) todefine the width 133 (6 to 24 inches (15 to 60 cm)) of the block 112.Additionally, each pair of side surfaces 128 a, 129 a, 128 b and 129 b,include a substantially vertical groove 134 located therebetween that isconfigured to receive a portion of a lateral support beam (see, forexample, the lateral support beam depicted in FIGS. 11, and 23-36).

The block 112 is that it is additionally provided with one or moresubstantially vertical apertures or through holes 150 a, 150 b, and 150c. As can be seen, apertures 150 a, 150 b, and 150 c, which are insubstantial alignment with the grooves 134 located on either side of theblock 112. This enables for use with support beams 270 such as thoseshown in (See FIG. 12), to be used, if desired. The vertical apertures150 a-c also allow a plurality of blocks 112 to be positioned in arunning bond (again using support beams 270 such as those shown in FIG.12, for example). The aperture 150 b may be provided with a slot 152,which that provides an opening to the rear face 122. In addition, theblock 112 may now be split into smaller predetermined sizes, with eachsmaller block (not shown) having a set of side grooves 134. Although notdepicted, it will be understood that apertures 150 a and 150 c may alsobe provided with slots (as with aperture 150 b), if desired.

Another feature of block 112 is the provision of recesses 127 a and 127b on the rear surface 122 adjacent the side surfaces 129 a and 129 b.The recesses come into play during, and aid in, the manufacturing of theblock. After a large block (not shown) is molded and split into twosmaller blocks and the smaller blocks are removed from the conveyor onwhich they rest by a pusher bar (not shown) that impacts the rearsurfaces of the blocks and moves them in a desired direction. This worksif the blocks are substantially parallel to the pusher bar. However, ifthe blocks are not substantially parallel to the pusher bar, the bar hasa tendency to chip and break the side segments. The recesses provideclearance so that if the block is somewhat askew relative to the pusherbar, the bar will not contact the side segments and thereby reducingchipping and breakage.

FIG. 8 shows a preferred corner configuration using the blocks 12 of thepresent invention. The design of the block 12 lends itself to theformation of corners without the need for mortar, corner braces, orother supports. Two blocks 12 a and 12 b are simply aligned to form acorner butt joint 51. Preferably, block 12 b is broken along itssplitting recess to form a new split face, which roughly matches splitfront face of block 12 a. Holes 54 are drilled through the blocks 12 aand 12 b so that a fastener 56 may be inserted therein. Generally, thefastener may be any suitable fastener, and preferably, an appropriatelysized pin, peg, or screw, and the like. Alternatively, glue, preferablyconstruction mastic, may be applied instead of or, more preferably, incombination with fasteners to secure the blocks to each other.

Referring now to FIGS. 9 and 10, another embodiment of a block 156 ofthe present invention is depicted. The block 156 is generallyangularly-shaped and includes a front face 158, a rear face 160, a topsurface 164, a bottom surface 166 and pairs of side surfaces 168 a, 169a, and 168 b, 169 b, respectively. As with the previously describedblocks 112, the side surfaces 168 a, 169 a, and 168 b, 169 b areprovided with grooves 170 a and 170 b that are configured to receiveportions of lateral support beams, and will not be discussed here indetail. An alternate embodiment of the block 156′ is illustrated inFIGS. 1-2 a. As shown in FIGS. 9-10, front face 158 is formed with aroughened or weathered surface or facing segments 159 a-b and isprovided with marginal areas 163 a-d. These features are not necessaryto carry out the spirit of the invention, however. The front face 158may be dressed, modified, or otherwise worked in any desired manner. Theblock 156 may also be provided with recesses 167 a and 167 b, located onthe rear face segments 161 a and 161 b, adjacent the side surfaces 169 aand 169 b. As discussed previously, the recesses 167 a-b prevent and/orreduce chipping during the manufacturing process.

As depicted, the block 156 is configured so that the front face segments159 a and 159 b, and the rear face segments 161 a and 161 b are orientedso that they intersect each other at a predetermined angle 172. Theangle of intersection 172 can vary from about 15 degrees to about 165degrees. Preferably, though, the angle of intersection is about 90degrees so that the block may be used to construct rectilinearstructures. In that regard, it will be appreciated that the blocks 156may be used with or without linearly shaped blocks to form columnarstructures of varying shapes and sizes (see, for example FIG. 1).Moreover, it is envisioned that the blocks may be formed with more thantwo front and rear face segments 159 a-b, 161 a-b, and/or that the blockcould be formed in a generally arcuate shape.

Referring now to FIG. 11, an embodiment of a beam of the presentinvention generally comprises an elongated spine or web and at least onerib, which is substantially coextensive therewith. More specifically, apreferred embodiment of beam 16, as shown, includes a plurality of ribsthat are arranged in a substantially coplanar and collateral relation.That is, there is a first pair of ribs 38 a, which are substantiallycoplanar and extend away from each other. And, there is a second pair ofribs 38 b, which are also substantially coplanar and extend away fromeach other. Note that the pairs of ribs 38 a and 38 b are in substantialcollateral relation with each other and are spaced apart from each otherby a distance defined by the web 36. This configuration of two pairs ofribs 38 a and 38 b attached to each other by web 36 forms somewhat of anI-beam configuration. It is preferred that at least one set of ribs 38 abe resiliently deformable and, even more preferred, that they convergeslightly towards and then diverge slightly away from the other ribs 38 bin a somewhat “V”-shaped configuration towards the ends of the ribs 38.A “V”-shaped configuration is preferred because it allows a segment 35of a block 12 to be gripped between the ribs 38 a-b (see, for example,FIGS. 23 and 24). As will be appreciated, in order for the desiredamount of gripping force to occur, the distance or span 42 between a rib38 b and the apex of the “V” of an unflexed rib 38 a should be slightlyless than the thickness of segment 35 (see FIG. 24). It will also beappreciated that the distance or span 43 between the leading edge offlange 40 of the unflexed rib 38 a and the rib 38 b should be slightlygreater than the thickness of segment 35 (See, again FIG. 24). Thus,when a beam 16 is attached to a block 12 the rib 38 a is deflected fromits unstressed state to a stressed state and a segment 35 of a block maybe gripped between ribs 38 a and 38 b. As depicted in FIG. 23 the ribs38 a and 38 b are preferred because they prevent unwanted movement andmisalignment between blocks 12 of a given column 14 and they are able tocompensate for variations in dimensions that sometimes occur duringmanufacture of the blocks.

Beam 16 may be attached at its upper ends to a structure being skirted(see, for example, FIG. 1) if desired, preferably at or near thelowermost edge or bottom of the structure, and using conventionalfastening techniques and technologies. Such attachments may be used inconjunction with or without a bracket 18 to provide support andstability to the independent columns 14 (see FIG. 5) by preventing themfrom leaning or falling forwardly or rearwardly. The beams aligns theblocks 12 of a given column), by preventing lateral movementtherebetween (that is, movement along the “x” direction in athree-dimensional coordinate system relative to the blocks 12).

Another embodiment of a lateral support beam 116 is depicted in FIG. 11a. Here, the beam 116 generally comprises a body having block-engagingportion and a bracket-engaging portion. More specifically, the beam 116comprises a first web 180 and a second web 181 that are generallyaligned with each other. Projecting from the webs 180, 181 are pairs ofribs 182 a, 182 b, and 182 c. The first pair of ribs 182 a, which formthe block-engaging portion, extend away from each other in a generallycoplanar relation. The second pair of ribs 182 b is generallycollaterally aligned with the first pair of ribs 182 a and is separatedtherefrom by a predetermined span 188. The third pair of ribs 182 c isgenerally collaterally aligned with the second pair of ribs 182 b and isseparated therefrom by a predetermined span 190. The outer ends of ribs182 a are provided with resilient flanges 184 that are configured andarranged such that the ribs 182 a are able to be received by thevertical grooves on the blocks. With this beam embodiment, segments ofthe sides of a block are not gripped between adjacent pairs of ribs.Rather, engagement with blocks is achieved through the first set of ribs182 a that substantially span the depth of the vertical grooves of theblocks, where depth is taken along the “z” axis in the three dimensionalcoordinate system (see, for example, FIG. 7 a). It will be appreciatedthat the block engaging portion, i.e., the first pair of ribs 182 a,need not be restricted to a flange configuration. A frictionalengagement, for example, can be achieved with other configurations.

Alternative embodiments of support beams 270, 287 and blocks 312 areillustrated in FIGS. 12, 13 and 27. With regard to the support beam 270depicted in FIG. 12, support beam 270 comprises a pair of webs 272, 274,which are generally parallel to each other and that terminate inopposing ribs. A third web 276 extends from the surface formed byopposing ribs in general alignment with webs 272, 274 and terminates inopposing ribs 278 c. The ends of opposing ribs 278 a and 278 b may beprovided with flanges and coupling elements 280, 282, respectively. Aswill be appreciated, two webs 272, 274 (versus a single web) increasesthe overall strength of the beam 270 so that the beam resists bendingand warping more than beams that have only single webs that connecttheir opposing ribs.

The support beam 287 of FIG. 13 is similar to the support beam 270 ofFIG. 12. Instead of having opposed ribs that engage a block, however,the block engagement section 288 of the beam is configured so that it isable to substantially span the depths of the grooves of two opposingblocks, or the depth of the aperture 350 in the interior section of ablock 312 (see FIG. 27) (where depth is taken along the “z” axis in thethree dimensional coordinate system as shown in FIG. 7 a). As depicted,the engagement section 288 of the support beam 287 is generally“T”-shaped and substantially spans the depth of the aperture 350 (i.e.see FIG. 27) where depth is taken along the “z” axis in the threedimensional coordinate system as shown in FIG. 7 a (see FIG. 45, forexample), and generally spans the width of the slot 352 of a block (see,FIG. 27). As shown, the engagement section 288 is hollow, however, it isunderstood that the engagement section 288 may be solid, if desired. Thebase of the “T”-shaped engagement section 288 is provided with a web 276and a pair of opposing ribs 278 c to enable the support beam 287 to beconnected to a bracket such as those depicted in FIGS. 44-45. Withregard to FIG. 27, it will be appreciated that the depiction of thesupport beams 270 and 287 relative to the blocks 312 are forillustrative purposes only, and that they may be interchanged ifdesired.

A frictional engagement may be desired and this could be achieved withother configurations. For example, in FIG. 14 the block-engaging section288 may take the form of generally planar opposing planar sections 192each having resilient spurs 194 projecting therefrom. Or, as seen inFIG. 15, the block-engaging section 288 may take the form of a preformedresilient body 196 having an aperture 198. Note that in FIGS. 14 and 15,the bracket-engaging portions 290 are shown in phantom.

With reference to FIG. 16, the support beam 116 is similar to thesupport beam of prior embodiments in that it includes a web 510 fromwhich a plurality of ribs 503, 504, 505 and 506 extend. In a departurefrom previous embodiments, the support beam 116 of this embodimentincludes an extension 508 that terminates with an attachment member 512.Preferably, the extension 508 is aligned with, and extends from the web510 so as to position the attachment member 512 a predetermined distancefrom the plurality of ribs 503, 504, 505 and 506. This arrangementserves several purposes. As explained above, not only does the extension508 create spaces between a wall structure and a substructure that maybe used as plenums, conduits, or for retaining insulative,fire-retardant or other building materials, but it also facilitatesattachment of the support beam 116 to a substructure. Preferably, theattachment member 512 comprises feet 516 and 518 that extend laterallyin opposite directions from the extension 508 to provide a point orpoints of connection which may be used with adhesive or fasteningelements, such as nails or screws, in attaching a support beam to asubstructure (see also, FIG. 29).

Referring now to FIG. 17, the support beam 116, again, has an extension508, which terminates in an attachment member 512 having feet 516, 518.However, in this embodiment, the extension 508 and the feet 516, 518 areforeshortened. Note that the support beam 116 is not directly connectedto a substructure but is operatively connected to a bracket 534 that is,in turn, operatively connected to a substructure. The bracket 534includes a substructure engaging portion 536, a span 538 and anattachment member with a support beam engaging portion 542. The supportbeam engaging portion 542 is sized to be snuggly received andfrictionally retained within a channel 530 or 532 formed by a rib and afoot 505, 516; 506, 518, respectively, of the beam 116. Note that thesupport beam 116 need not extend along the length of the bracket 534,and more particularly, the support beam 116 need not be coextensive withthe side of a block 112 (see FIG. 7 a) to which it may be operativelyconnected. The reason for this is that a block need not be retainedalong its entire length of its grooves to be adequately retained as partof a wall structure. Instead, it is only necessary for a block toretained at several points. Thus, the support beams 116 may take theform of clips that attach to the bracket 534, and a block 112 can beretained at a plurality of predetermined locations (i.e. such as upperand lower ends). It will be appreciated that such support beam clips maybe used to operatively connect a pair of blocks to a support bracket bypositioning the clips so that they span the interface between twoadjacent blocks. It will also be appreciated that the support beam clipmay be longer than a side of a block to which it is operativelyconnected so that it may operatively connect more than two blocks to abracket.

The span 538 of the bracket 534 serves to position the support beam 116a predetermined distance from a substructure while the substructureengaging portion 536 serves to attach the bracket 534 to a substructure.As with the aforementioned embodiment, the bracket 534 may beoperatively connected to a substructure using a variety of fasteningelements. It will be appreciated that both channels 530, 532 of thesupport beam 116 of this embodiment may be used with oppositely facingbrackets, if desired, to form a more robust connection between the wallstructure and a substructure.

Referring now to FIG. 18, the support beam 116 terminates at anattachment member 512 that includes two spaced apart resilient walls550, 552 having confronting arms 554, 556, which define a slot 558 andchannel 560, which are sized to admit and retain a second attachmentmember.

With this embodiment, the support beam 116 is not directly connected toa substructure but is operatively connected to a bracket 562 that is, inturn, operatively connected to a substructure (see, for example, FIG.32). The bracket 562 includes substructure engaging portions 564, 566, aspan 538 and a first attachment member 570. Preferably, the firstattachment member 570 is a dart-shaped head 572 having shoulders 574,576 that are configured to engage arms 554, 556 of the support beam 116in a constrained relation. That is, the attachment member 512 of thesupport beam is sized to slidingly receive the head 572 within a slot558 and a channel 560 formed by the resilient walls 550, 552 and theirconfronting arms 554, 556. Thus, the support beam 116 may be connectedto a bracket 562 in a constrained manner. It will be appreciated thatthe support beam 116 can be operatively connected to the bracket 562 inseveral ways. For example, by positioning the bottom of the channel 560and the slot 558 over the top of the dart shaped head 572 and the span568 of bracket 562 and then sliding the support beam 116 down along thebracket 562 and interconnecting with an already positioned block, orsliding the support beam down along the bracket 562 and laterinterconnecting with a block, which is slid into position in a similarmanner. Alternatively, a support beam 116 may be operatively connectedto a bracket 562 by aligning the slot 558 of the attachment member 512opposite the apex of the dart shaped head 572 and then pushing thesupport beam 116 towards the dart shaped head 572 until the arms 554,556 of the attachment member 512 engage the shoulders 574, 576 of thedart shaped head 572.

As will be appreciated, the support beam 116 of FIG. 18 need not extendalong the length of the bracket 562 and, more particularly, the supportbeam need not be co-extensive with the side of a block to which it isoperatively connected. The span 538 of bracket 562 serves to positionthe support beam 116 a predetermined distance from a substructure andthe substructure engaging portion 564, 566 serves to attach the bracket562 onto a substructure. Bracket 562 may be operatively connected to asubstructure using a variety of fastening elements 578 (see also, FIG.32).

Referring now to FIG. 19, the operative connection is reversed from thatshown in FIG. 18. That is, support beam 116 includes an extension thatterminates in a first attachment member 570 having a head 594 withshoulders 596, 598. The bracket 580 now includes two spaced-apartresilient walls 582, 584 having confronting arms 586, 588, which definea slot 590 and a channel 592, which are sized to admit and retain theattachment member 594 in a constrained relation, as discussed above. Aswith the aforementioned embodiments, the support beam 116 need notextend along the length of the bracket 580. The bracket may beoperatively connected to a substructure using a variety of fasteningelements.

Referring now to FIG. 20, another preferred embodiment depicts a post600 which has been provided with a plurality of connectors to enable thepost 600 to support a plurality of wall structures. In this embodiment,the post 600 includes front and rear surfaces 602, 604 and opposingsides, with a web 606 that extends from the front surface 602, and anattachment bracket 612 that extends from the rear surface 604. A pair ofribs 608, 610 extend laterally in opposite directions from the web 606in the same manner as the ribs 38 of support beam 16 in FIG. 11, whilethe attachment bracket 612 includes a slot 614 and channel structure 616similar to the slot 558, 590 and channel 560, 592 structures describedand shown in FIGS. 18 and 19, respectively. Thus, with this embodiment,blocks may be directly connected to the post 600 at side 602 orconnected indirectly at side 604 via an appropriately configured supportbeam (such as beam 116 of FIG. 19).

Although not shown, other combinations of operative connections may alsobe used. For example, the post 600 may be provided with two directconnectors (webs with laterally extending ribs) or the post may beprovided with two indirect connectors (attachment members, such aschannels). As will be appreciated, the post 600 may be operativelyconnected to a substructure such as a footing or foundation, or be setinto the ground using known techniques and technologies. While the post600 is depicted as having a hollow cross-section, it is understood thatthe post may also be a solid in cross section or may have a reinforcingstructure such as a pipe or a rod received therein.

With reference to FIG. 21, the support beam 116 is similar to thesupport beam of prior embodiments, in that it includes a web 510 fromwhich a plurality of ribs 503, 504, 505 and 506 extend. The support beam116 includes an extension 508 that terminates with an attachment member512. Preferably, the extension 508 is aligned with, and extends from theweb 510 so as to position the attachment member 512 a predetermineddistance from the plurality of ribs 503, 504, 505 and 506. In FIG. 21,the attachment member 512 is depicted as feet 516 and 518, however it isunderstood that the attachment member may take other forms. Note thatribs 503, 504, 505 and 506 are reversed relative to each other so thatthe pair of opposing ribs 505 and 506 are now forward, relative to theopposing pair of ribs 503 and 504 (similar to the rib arrangement asdepicted in FIGS. 23 and 24). Note also, that the pair of forwardlyfacing opposing ribs 505 and 506 are somewhat thicker than the pair ofopposing ribs 503 and 504. This feature allows the support beam 116 tohave a viewable surface 507, which may form part of an observed wallstructure (see FIG. 35).

Referring now to FIG. 22, a partial horizontal section of the wallstructure 10 of FIG. 4 is depicted. As shown, a beam 16 operativelyconnects two adjacent blocks 12 of adjacent columns 14 to each other.Here, the “V”-shaped ribs 38 a are positioned within grooves 34 ofadjacent blocks 12 and ribs 38 b are positioned against the rear faces22 of adjacent blocks 12. In this configuration, the beam 16 remainshidden from view and provides support along several axes (taken alongthe “z” and “x” directions in a three-dimensional coordinate systemrelative to a block 12). With the beam 16 of this embodiment, thegrooves 34 may be considerably larger than the thickness of the ribs 38a, without affecting the gripping ability of the beam 16. Thus, theremay be quite a large space in front of the ribs 38 a. Note that thedistance between side surfaces 29 a and 29 b of block 12 is less thanthe distance between side surfaces 28 a and 28 b of block 12 to allowthe side surfaces 28 a, 28 b of adjacent blocks 12 to be brought intointimate contact with each other while providing enough space toaccommodate the web 36 of the beam 16 (see FIGS. 24 and 24 a). Note thata bracket 18 is shown (in dashed lines) as it would be positionedrelative to an uppermost block 12 of a column 14.

FIGS. 23 and 24 show a preferred beam arrangement in which the beam 16shown in FIGS. 11 and 22 is reversed with respect to blocks 12 to whichthe beam is connected. That is, the ribs 38 b are positioned withinopposing grooves 34 and ribs 38 a are positioned against the rear faces22 of blocks 12. This arrangement does not significantly change thefunction and gripping ability of the beam 16 as discussed above.

As with to the embodiment depicted in FIG. 22, the distance between sidesurfaces 29 a and 29 b of the blocks is less than the distance betweenside surfaces 28 a and 28 b to allow side surfaces 28 a, 28 b ofadjacent blocks 12 to be brought into intimate contact with each otherwhile providing enough space to accommodate the web 36 of the beam 16.Note that when two adjacent blocks 12 are brought into contact with eachother, their corresponding margins 23 a and 23 b combine to form aprofile that is substantially the same as the profile of a splittingrecess 21 (as shown in FIGS. 22 and 24). It will be appreciated that thesplitting recess 21 and may have other profiles, such as a “V”-shape andthat the corresponding margins would be more beveled or chamfered.

Referring now to FIGS. 23, 23 a, 24 and 24 a, operatively connectingblocks together to form a wall structure 10 begins with connecting ablock 12 to a beam 16. As depicted in FIGS. 23 a and 24 a, the leadingedge of flange 40 allows the rib 38 a to be displaced as it encountersthe block segment 35. As the beam 16 is connected to the block 12, blocksegment 35 is gripped by ribs 38 a and 38 b.

In a preferred method to operatively connect a wall to a structure usingthe aforementioned bracket, a person would prepare or otherwise selectan appropriate location in which to construct a wall. The constructionwould begin by placing a first block having opposing side grooves in adesired position and orientation. Then, a second, similar block would beplaced directly on top of the first block so that the opposing sidegrooves of the first and second blocks are in vertical alignment witheach other and the first and second blocks form a column. Next, thefirst and second blocks would be operatively connected to each otheralong one of their respective sides by inserting a rib of first supportbeam into the aligned grooves and seating it securely.

Next, a bracket is positioned so that its wall engaging portion iscollaterally aligned and in contact with the support beam such that itextends therewith along the groove in the block. The structure engagingportion of the bracket is then brought into position for attachment to astructure by sliding or otherwise manipulating the bracket in adirection towards the point of attachment on the structure (this isgenerally above and co-planar with the wall). The bracket is thanattached to the structure using conventional techniques andtechnologies. The rib of a second support beam is then inserted into thealigned grooves of the opposite sides of the blocks, and a secondbracket is used to operatively connect this portion of the wall to astructure using the aforementioned steps.

A second column comprising similarly configured third and a fourthblocks may now be constructed. The operation is much the same, exceptnow the third block is positioned so that one of its sides is adjacentto one of the sides of the first block and its groove engages at leastone other rib of one of the already positioned support beams. The fourthblock is then positioned on top of the third block in a similar manner.That is, the fourth block is positioned so that one of its sides isadjacent to one of the sides of the second block and its groove engagesat least one other rib of one of the already positioned support beam andthe wall engaging portion of the already installed bracket.

After the second column is erected, the third and fourth blocks would beoperatively connected to each other along their respective free side byinserting at least one rib of a third support beam into their alignedvertical groove of the respective sides of the first and second blocksand seating them securely, and that support beam would be operativelyconnected to a support by yet another bracket. And so on. It will beappreciated that other methods of constructing a wall structure usingthe aforementioned components are possible.

FIG. 25 illustrates an alternative embodiment of a beam 16 having tworibs 38 a, 38 b but only one resiliently deformable rib 38 a. FIG. 26shows yet another embodiment of a beam 16 comprising one pair of opposedribs 38 b such that the support beam 16 is essentially an elongatespline. It should be understood that for purposes of clarity, the ribs38 b as depicted in FIGS. 25 and 26 are substantially thinner than thegrooves 34 in which they are positioned, and that in actuality ribs 38a-b and grooves 34 would be configured to effectively maintain blocks 12in a coplanar relation with little or no play.

Alternative embodiments of support beams and blocks are shown in FIG.27. As depicted in FIG. 27, a support beam 270 may be operativelyconnected to one or more blocks 312, at grooves 334 a and 334 b. Notethat the blocks 312 include a front face 320, a rear face 322, a topsurface 324, a bottom surface (not shown), and side surfaces 328 a and329 a, and 328 b and 329 b. The blocks 312 also include marginal areas323 and notches 327, which will not be discussed here in detail. As canbe seen, the side surfaces 329 a and 329 b are foreshortened toaccommodate the increased width of the support beam 270. The supportbeam 270 may be operatively connected to a block 312 when the ribs 278 aand 278 b grip side segments 335 a, 335 b. The support beam 287 can beoperatively connected to a block 312 by sliding a block engagementsection 288 into the aperture 350.

Another embodiment of a lateral support beam is depicted in FIG. 28.Here, the beam 116 generally comprises a body having block-engagingportion and a bracket-engaging portion. More specifically, the beam 116comprises a first web 180 and a second web 181 that are generallyaligned with each other. Projecting from the webs 180, 181 are pairs ofribs 182 a, 182 b, and 182 c. The first pair of ribs 182 a formblock-engaging portions, which extend away from each other in agenerally coplanar relation. The second pair of ribs 182 b is generallycollaterally aligned with the first pair of ribs 182 a and is separatedtherefrom by a predetermined span 188. The third pair of ribs 182 c isgenerally collaterally aligned with the second pair of ribs 182 b and isseparated therefrom by a predetermined span 190. The outer ends of ribs182 a are provided with resilient flanges 184 that are configured andarranged such that the ribs 182 a are able to be received by thevertical grooves on the blocks of the present invention. With thisembodiment, segments of the sides of a blocks re not gripped betweenadjacent pairs of ribs.

Now referring to FIG. 29, a support beam 116, similar to the supportbeam of prior embodiments, includes a web 500 from which a plurality ofribs 503, 504, 505 and 506 extend. The support beam 116 of thisembodiment includes an extension 508 that terminates with an attachmentmember 512. Preferably, the extension 508 is aligned with, and extendsfrom the web 500 so as to position the attachment member 512 apredetermined distance from the plurality of ribs 503, 504, 505, and506. The extension 508 not only creates spaces between a wall structureand a substructure that may be used as plenums, conduits, or forretaining insulative, fire-retardant or other building materials, andalso facilitates attachment of the support beam 116 to a substructure“S” (partially shown). Preferably, the attachment member 512 comprisesfeet 516, 518 that extend laterally in opposite directions from theextension 508 to provide a point or points of connection which may beused with adhesive or mechanical fastening elements, such as nails orscrews 522, in attaching a support beam to a substructure “S”.

FIG. 30 illustrates a partially assembled wall structure 410 comprisinga plurality of blocks 412 retained in place by a plurality of verticallyoriented, elongated support beams 416 that are operatively connected toa substructure “S” (shown in dashed lines). The support beams 416 allowthe blocks 412 of adjacent horizontal courses to be substantiallysuperposed one above the other and not laterally offset from each otherin a bond pattern, as one may expect of such a wall structure. Thus, thewall structure 410 is comprised of a plurality of adjacent columns 414a-d that may be operatively connected to each other in a serial fashion.Each block 412 of the wall structure 410 includes a front face 420, arear face 422, a top surface 424, a bottom surface 426 and opposingsides 427 a, 427 b. Each opposing side 427 a, 427 b includes opposinggrooves 434, 436 defined by plurality of outwardly extending fingers 428a, 428 c and 428 b, 428 d, with outwardly facing surfaces 430 a, 430 cand 430 b, 430 d.

Preferably, the blocks 412 are symmetrically formed, so that either thefront or rear face 420, 422, respectively, may face forwardly. Thisfeature allows a block which has been damaged or had its surfaceotherwise altered to be easily removed and reinstalled by merely turningthe block around (or over) so that other good or undamaged sides nowbeing the viewable surface of the block. In other words, the blocks arereversible. The front and rear faces need not have the same surfacetreatment. That is, a block 412 may have a smooth front face and aroughened rear face 422. Or, a block 412 may have roughened front faceand a decorated or non-planar rear face. For example, in FIG. 30, thelower most blocks 412 of column 414 c and column 414 d, respectively,have forwardly facing rear faces 422 while the remaining blocks in thepartially assembled wall structure 410 have forwardly facing frontfaces. As depicted, the viewable front faces 420 of the blocks 412 ofthe wall structure 410 are smooth and the viewable rear faces 422 of theblocks of the wall structure 410 are roughened or otherwise decorated.Note that the leftmost beam 416 may be used to form the base and a capof a horizontally oriented wall structure.

Referring now to FIG. 31, a support beam 116, has an extension 508,which terminates in an attachment member 512—with feet 516, 518.However, in this embodiment the extension 508 and the feet 516, 518 areforeshortened. Note that, the support beam 116 is not directly connectedto a substructure “S” but is operatively connected to a bracket 534 thatis, in turn, operatively connected to a substructure “S” (shown indashed lines). The bracket 534 includes a substructure engaging portion536, a span 538 and an attachment member with a support beam engagingportion 542. The support beam engagement portion 542 is sized to besnuggly received and frictionally retained within a channel 530 or 532formed by a rib and a foot (505, 516; 506, 518, respectively) of thebeam 116. Note that the support beam 116 need not extend along thelength of the bracket 534, and more particularly the support beam neednot be coextensive with the side of a block to which it is operativelyconnected. The reason for this is that a block 112 need not be retainedalong its entire length of its grooves to be adequately retained as partof a wall structure. Instead, it is only necessary for a block toretained at several points. Thus, the support beams 116 may take theform of clips that attach to the bracket 534, and a block 112 may beretained at a plurality of predetermined locations such as its upper andlower ends. It will be appreciated that such support beam clips may beused to operatively connect a pair of blocks to a support bracket 534 bypositioning the clips so that they span the interface between twoadjacent blocks. It will also be appreciated that the support beam clipmay be longer than a side of a block to which it is operativelyconnected so that it may operatively connect more than two blocks to abracket.

The span 538 of the bracket 534 serves to position the support beam 116a predetermined distance from a substructure “S” while the substructureengaging portion 536 serves to attach the bracket 534 onto asubstructure “S”. As with the aforementioned embodiment, the bracket 534may be operatively connected to a substructure “S” using a variety offastening elements. It will be appreciated that the support beam 116 ofthis embodiment may be used with oppositely facing brackets, if desired,to form a more robust connection between the wall structure and asubstructure “S”.

Referring now to FIGS. 32 and 18, the support beam 116 does not have anextension. Rather, as best shown in FIG. 18, the beam 116 terminates ata first attachment member 512 that includes two spaced apart resilientwalls 550, 552 having confronting arms 554, 556, which define a slot 558and channel 560 that are sized to admit and retain a second attachmentmember 570.

With this embodiment, the support beam 116 is not directly connected toa substructure “S” but is operatively connected to a bracket 562 thatis, in turn, operatively connected to a substructure “S” (shown indashed lines). The bracket 562 includes substructure engaging portions564, 566, a span 538 and an attachment member 570. As best shown in FIG.18, the attachment member 570 is dart-shaped head 572 having shoulders574, 576, which are configured to engage confronting arms 554, 556 in aconstrained relation. That is, the attachment member 570 of the supportbeam is sized to slidingly receive the dart shaped head 572 within aslot 558 and channel 560 formed by the resilient walls 550, 552 andtheir confronting arms 554, 556. Thus, the support beam 116 may beconnected to the bracket 562 in a constrained manner. It will beappreciated that the support beam 116 may be operatively connected to abracket 562 in several ways. For example, by positioning the bottom ofthe channel 560 and the slot 558 over the dart shaped head 572 of thebracket 562, the support beam 116 may be slid down along the bracket 562to interconnect with an already positioned block 112. Alternatively, thebeam 116 may be slid down along the bracket 562 and laterinterconnecting with a block 112, which is slid into position in asimilar manner. Alternatively, a support beam 116 may be operativelyconnected to a bracket 562 by aligning the slot 558 of the attachmentmember 512 opposite the apex of the dart shaped head 572 and thenpushing the support beam 116 towards the dart shaped head 572 until theconfronting arms 554, 556 of the attachment member 512 engage theshoulders 574, 576 of the dart shaped head 572.

The support beam 116 need not extend along the length of the bracket562, and, more particularly, the support beam need not be co-extensivewith the side of a block to which it is operatively connected. Thereasons for this have been discussed in conjunction with the descriptionof FIG. 31, and for purposes of brevity will not be repeated. The span538 of the bracket 562 serves to position the support beam 116 apredetermined distance from a substructure “S” and the substructureengaging portion 564, 566 serves to attach the bracket 562 to asubstructure “S”.

Referring now to FIGS. 33 and 19, the operative connection is reversedfrom FIG. 32. That is, the support beam 116 includes an extension 508that terminates in an attachment member 570 having a dart-shaped head594 with shoulders 596, 598. The bracket 580 includes two spaced-apartresilient walls 582, 584 having confronting arms 586, 588, which definea slot 590 and channel 592 that are sized to admit and retain thedart-shaped attachment member 594 in a constrained relation, asdiscussed above. As with the aforementioned embodiments, the supportbeam 116 need not extend along the length of the bracket 562, and thebracket 562 may be operatively connected to a substructure “S” using avariety of fastening elements.

With reference to FIGS. 34 and 35, support beam 116 depicted is similarto the support beam of prior embodiments in that it includes a web 510from which a plurality of ribs 503, 504, 505 and 506 extend. In adeparture from this previous embodiment, the support beam 116 includesan extension 500 that terminates with an attachment member 512.Preferably, the extension 500 is aligned with, and extends from the web510 so as to position the attachment member 512 is a predetermineddistance from the plurality of ribs. Note that the ribs 503, 504, 505and 506 are reversed relative to each other so that the pair of opposingribs 505 and 506 are now forward relative to the opposing pair of ribs503 and 504. In FIG. 34, the attachment member 512 is depicted as havingfeet 516 and 518, however it is understood that the attachment membermay take other forms such as those depicted in FIGS. 18-20. Note also,that the pair of forwardly facing opposing ribs 505, 506 are somewhatthicker than the pair of opposing ribs 503, 504. This feature allows thesupport beam 116 to have a viewable surface 507, which may form part ofan observed wall. As depicted in FIGS. 34 and 35, ribs 505 and 506 maybe coplanar or collateral relative to the viewable faces 320, 322 ofblocks in a wall structure.

Referring again to FIGS. 34 and 35, the blocks 312 that are used withthe aforementioned beam 116 are similar to the blocks 112 depicted inthe wall construction 110 of FIG. 30. That is, each block 312 has afront face 320, a rear face 322, a top surface, a bottom surface andopposing sides.

Each block 312 differs from the block 112 depicted in FIG. 30 in severalrespects. First, block 312 has only one pair of opposing fingers 328 a′,328 b′ instead of the pair of opposing fingers depicted in FIG. 33.Thus, each block 312 does not have a groove that obscures a support beamrib. Instead of a groove, each block 312 has opposing ledges 334, 336defined by pairs of side surfaces 330 a, 330 b, 330 c, 330 d and fingers328 a′, 328 b′, respectively. Preferably, the thickness of the ledges336, 338 will be substantially the same as the thickness of opposingribs 505, 506 to enable the viewable surface of a wall structure to besubstantially contiguous. However, it is understood that the thicknessesof the ledges 336, 338 and/or opposing ribs 505, 506 need not besubstantially the same. For example, the thickness of the ribs 505, 506may be greater than the thickness of the ledges 336, 338 of the blocksso that the viewable surface 507 of a support beam projects outwardlywith respect to the viewable surface of the blocks of the wall structure(as in FIG. 35), or the thickness of the ribs 505, 506 may be less thanthe thickness of the ledges 336, 338 of the blocks so that the viewablesurface 507 of the support beam is recessed with respect to the viewablesurface.

Another difference between block 312 and block 112 is that the opposinglaterally extending, aligned fingers 328 a′, 328 b′ are offset from thecenter plane of the block 312. As seen in FIGS. 34 and 35 this allowsblocks to be operatively connected to a support beam in severalconfigurations. In FIG. 34, for example, blocks 312 are operativelyconnected to a support beam so that front face 320 (left side) and rearface 322 (right side) are substantially flush with the viewable surface507 of the support beam 116. As with the aforementioned blocks of FIG.30, the front and rear faces may have the same surface or differentsurfaces. Here, the front face 320 on the left side of FIG. 34 isdepicted as being smooth, while the rear face 322 on the left side ofFIG. 34 is depicted as being roughened. The viewable surfaces on theright side of FIG. 34 are reversed. In FIG. 35, the blocks 312 have beenrotated so that when they are operatively connected to the support beam116 they are set back from the viewable surface 507. It will beappreciated that the blocks 312 need not be all coplanar or set backwith respect to the viewable surface 507 of the support beam 116.Combinations of setback blocks and coplanar blocks are possible tocreate a myriad of wall surfaces. It is contemplated that suchcombinations may be arranged into identifiable forms or patterns and mayalso be arranged to display alphanumeric characters and the like. Notethat the viewable surface 507 may be provided with a textured orotherwise decorated surface, which matches the surfaces of adjacentblocks. Alternatively, as depicted in FIG. 34, the forward facingsurface of the support beam can be provided with a cap or strip 145 ofmaterial with a viewable surface 147, which may be textured or otherwisedecorated as desired and which may be affixed or attached to theviewable surface 147 in a conventional manner.

Referring now to FIG. 36, another preferred embodiment depicts a post600, which has been provided with a plurality of connectors to enablethe post to support a plurality of wall structures. In this embodiment,the post 600 includes opposing sides 602, 604 from which extend a web606 and a bracket 612, respectively. A pair of ribs 608, 610 extendlaterally in opposite directions from the web 606, while the bracket 612includes the slot 614 and channel structure 616 similar to the slot andchannel structures described and shown in FIG. 18, respectively. Thus,with this embodiment, blocks may be directly connected to the post 600at side 602 or connected indirectly at side 604 via an appropriatelyconfigured support beam.

Other combinations of operative connections may also be used. Forexample, the post 600 may be provided with two direct connectors (webswith laterally extending ribs) or the post may be provided with twoindirect connectors (attachment members, such as channels). As will beappreciated, the post 600 may be operatively connected to a substructuresuch as a footing or foundation, or be set into the ground using knowntechniques and technologies. While the post 600 is depicted as having ahollow cross-section, it is understood that the post may also be a solidin cross-section or may have a reinforcing structure such as a pipe or arod received therein (see, for example, FIG. 39).

FIGS. 37-37 b illustrate additional embodiments of the presentinvention. FIG. 37 shows a support beam 16 having a pair of legstructures 654 that are constructed and arranged to secure a wallcomprising columns 14 of blocks 12 to an existing support structure 658.The support structure 658 may be a building or any other type ofstructure that may support a wall structure 10 according to the presentinvention. Legs or leg portions 656 of the leg structures 654 extendrearwardly from the support beam 16 and are preferably secured to ribs38 b thereof. The leg structures 654 may also be formed as part of theweb 36 of the support beam 16. The leg portions 656 have a foot 660,which extends laterally therefrom to provide a point of connection forthe support beam 16 to the existing support structure 658. Nails,screws, or other appropriate fasteners 662 may be driven through thefeet 660 of the support beam 16 and into the sheathing 664 of thetypical wall of the wall of the existing structure 658. The sheathing664 is typically supported by a plurality of horizontal girts 666. Oncethe support beam 16 has been secured to the existing structure 658,blocks 12 are stacked between respective support beams 16 as illustratedin FIG. 37 such that ribs 38 a of the support beam 16 reside in grooves34 in the sides of the blocks 12.

In order to prevent the inflow of water into the wall structure 10, itmay be desirable to apply a bead of a waterproof material 670, such asmastic or caulk, along the horizontal surfaces of the blocks 12. Thebead of waterproof material 670 forms a seal between the upper surface24 of the lower block 12 upon which the waterproof material 670 has beenapplied and the lower surface 26 of the block 12 immediately above thelower block 12. It will be appreciated that mastic or caulk may also beapplied to the vertical side surfaces of the blocks (not shown).

Legs or leg portions 656 of support beam 16 preferably extend rearwardlyfrom the ribs 38 b in a perpendicular relationship thereto. Similarly,it is preferred that the feet 660 of the support beam 16 extendlaterally perpendicular to the leg portions 656. The perpendicularrelationship of the feet and legs to the remainder of the support beam16 is the preferred embodiment thereof since the purpose of the legportions 656 and the feet 660 to provide an offset for the wallstructure from the existing structure 658. This offset allows a wallstructure 10 to be secured over uneven surfaces such as corrugated steelsiding 668, as illustrated in FIG. 37. As can be seen, legs or legportions 656 of support beam 16 are sufficiently long such that thesupport beam 16 clears ridge 673 of the steel siding 668. As can beappreciated, steel siding 668 typically presents a plurality ofvertically flat attachment surfaces. Where a wall structure 10 is to beapplied to a wall of an existing structure 658 that is not verticallysmooth, furring strips or blocking may be fastened to the wall ofexterior of the existing structure 658 as needed. As support beams 16provide no vertical support for the blocks 12, the blocks must beprovided with some sort of foundation. Examples of suitable foundationinclude, but are not limited to, a concrete pad or footing that is sunkinto the ground, and a cantilever ledge or bracket which is securelyaffixed to the wall of the existing structure.

FIG. 37 a illustrates a support beam 16 having two pairs of ribs 38 aand 38 b separated by a web 36 and only a single leg structure 654comprising a leg portion 656 and a foot 660. The embodiment of FIG. 37 ais particularly useful when an obstruction, such as ridge 673 of steelsiding 668 would prevent one of the leg structures 654 illustrated inFIG. 37 from securely contacting the wall of the structure 658.Fasteners 662 are sufficient to provide the requisite lateral supportfor the wall structure 10. The support beam 16 having only a single legstructure 654 may be rotated end-for-end depending on the offsetlocation of an obstruction such as ridge 673.

Preferably, the support beams of the present invention will be extrudedor molded from a material such as a plastic, a fiber reinforced resin,or a metal such as aluminum. In addition to forming embodiments ofsupport beams 16 having the respective profiles of the support beamsillustrated in FIG. 37 a, it is possible that one leg structure 654could be removed from a support beam 16 such as the support beam 16 ofFIG. 37 having two leg structures 654, thereby resulting in the supportbeam 16 embodiment illustrated in FIG. 37 a. However, where a single legstructure 654 would be sufficient to provide the needed lateral supportfor a wall structure 10, it would be more economical to manufacturesupport 16 having only a single leg structure 654. As used herein, theterm “forward” means away from the center of the elevated structure (andalong the “z” direction in a three-dimensional coordinate systemrelative to a block) and the term “rearward” means toward the center ofthe elevated structure (also along the “z” direction in athree-dimensional coordinate system relative to a block).

FIG. 37 b illustrates a support beam 16 that is constructed and arrangedto provide lateral support to a wall structure 10 as described inconjunction with FIGS. 37 and 37 a. The main difference here being thatthe support beam 16 of FIG. 37 b has a pair of ribs 38 a and only asingle rib 38 b extending from the web 36. A leg structure 654 extendsrearwardly from the rib 38 b preferably in a perpendicular relationthereto. While it is preferred that the leg or leg portion 656 and foot660 be arranged at right angles to each other and to the ribs 38 b ofthe support beam 16, these structures may be arranged at any angle toone another provided, of course, that there is a sufficient offset fromthe wall of the existing structure 658 to allow installation of theblocks 12 of the wall structure 10 and that the foot 660 of legstructure 654 may be securely fastened to an supporting structure 658.

FIG. 38 illustrates a double-ended support beam 80 b, which is usefulfor constructing a dual wall structure 10 having a front face 74 and arear face 76. The space between the front and rear faces 74, 76 of thewall structure 10 may remain hollow or may be filled. Each end of thedouble-ended support beam 80 b comprises a support beam or blockengagement structure having a cross-sectional profile similar to thesupport beam illustrated in FIG. 11 arranged back-to-back in a spacedapart relation and connected by a spacer web 82 b. Spacer web 82 b isconnected to the base pair of ribs 38 b of each of the support beamportions in a perpendicular fashion. In this manner, support beam 80 bcouples dual walls of the wall structure 10 to provide mutual lateralsupport. Further support can be had by backfilling the space between thefront and rear sides of the dual wall structure 10 with gravel, earth,sand, concrete or insulative material 79. Preferably, it will beappreciated that a cap 81, such may be placed over the top of the dualwall structure 10 to prevent the ingress of water, debris, or nuisanceanimals. It will also be appreciated that such a cap 81 may be securedto the dual wall structure by known technologies and techniques, ifdesired. See, for example, the use of adhesive material depicted in FIG.37.

FIG. 39 illustrates a single-sided wall structure 10 comprising columns14 of blocks 12 supported by a post-like support beam 84. Support beam84 comprises a post 85 having extending therefrom a web 36. A pair ofribs 38 a extend laterally from the web 36 in the same manner as theribs 38 a of support beams 16 described in conjunction with FIG. 11. Asinstalled, post 85 is preferably rigidly seated in a footing orfoundation set into the ground below the wall structure 10. As can beappreciated, blocks 12 are stacked between respective post support beams84 as described above. The post 85 preferably has a hollowcross-section. However, post 85 may also be solid in cross-section or beprovided with a reinforcing structure such as a pipe or a rod receivedtherein. An alternate embodiment for the post or support beam 84involves securely seating a plurality of rods or members in footings ora foundation beneath the wall structure 10 and sliding the post or beam84 of the type illustrated in FIG. 39 thereover. Blocks 12 would thendisposed between respective pairs of post support beams 84 as describedabove.

Now turning to FIG. 40, a wall structure 10 is depicted as it may beused in conjunction with an elevated structure “S.” As with the wallstructure generally depicted in FIGS. 4 and 22, this wall structure 10is comprised of a plurality of blocks 12 arranged in columns 14, havingthe columns 14 held in place by vertically oriented, lateral supportbeams 16, and with each beam 16 operably connecting adjacent columns 14together. The brackets 19 used in this embodiment, however, differ fromthe “U”-shaped brackets 18 of the previously described embodiment inseveral respects. First, the brackets 19 are shaped differently than thebracket 18 of FIGS. 4 and 22. Instead of having an inverted “U”-shapedconfiguration as with bracket 18, the bracket 19 of this embodiment hasa single, downwardly extending portion. Another difference is thatrather than positioning a portion of a block 12 within an opening 50defined by a pair of walls 44, 46, the bracket 19 of the embodiment hasa wall engaging portion 62 that extends downwardly into vertical grooves34 at the sides of blocks 12. Another difference between brackets 18 and19 is that bracket 18 connects to a column 14 in a generally centrallocation, whereas the brackets 19 of this embodiment connect at thesides of column 14. As with the previously described brackets 18,brackets 19 help to stabilize and prevent the wall structure 10 fromtipping rearwardly or forwardly. The brackets 19 also prevent thestructure from shifting from side to side.

For purposes of illustration, the size of the wall structure 10 of thisembodiment has been limited three columns 14 and four courses, with thetwo uppermost blocks of the left column 14 removed to reveal thejuxtaposition between the brackets 19, beams 16 and blocks 12. Note thatthe wall structure 10 depicted in this embodiment also includes aplurality of footings or support pads 80 a that are positioned beneaththe columns 14 at the junction where they connect to the beams 16.Preferably, each footing or support pad 80 a may be provided with asetting channel 82 a that is configured and arranged to receive thebottom edges of one or more columns of blocks in a constrained relation.Note that the footing or support pad 80 a for the middle and rightcolumns 14 has been removed and replaced with an “L”-shaped support baseor angle iron (see, for example, the support base in FIGS. 3 and 53)that spans the bottom of the middle and right columns 14. Thisconstruction can be used when the use of individual, regularly spacedfootings 80 a is not possible or desirable. Also note that the wallstructure 10 is depicted as having a running bond on its three lowermostcourses. As can be seen, the bottom and third courses of blocks do nothave splitting recesses. They do, however, have their perimeter marginalareas 23 a-d worked. The second course of blocks, on the other hand,have splitting recesses 21 and have only their horizontal marginal areasworked. Thus, each column 14 will have blocks with alternating frontfaces. When the columns of blocks are positioned adjacent each other inthe normal assembly procedure some of the blocks 12 will form tightjoints 31 and some of the blocks will form joints that appearsubstantially thicker. Thus, from a distance, the wall structure 10 willgive the impression that it was constructed of blocks and mortar in aconventional manner. It will be appreciated that the externally viewablesurface of the wall structure depicted in FIG. 40 is merely one exampleof an externally viewable surface, and that many other externallyviewable surfaces are possible.

Turning now to FIGS. 41-43, a preferred embodiment of bracket 19depicted in FIG. 40 will now be discussed. As can be seen in FIGS. 41and 42, the bracket 19 comprises a structure engaging portion 60 and awall engaging portion 62. The wall engaging portion 62 of the bracket 19includes opposing surfaces 64, 66, which are arranged and configured tocontact a portion of a beam 16 and a portion of a block, respectively.If desired, the wall engaging portion 62 may be provided withstrengthening creases 67. As will be appreciated, the wall engagingportion 62 of the bracket 19 has a width 77 and a length 78 whosedimensions correspond to the particular blocks that are being used toconstruct a wall, and will be discussed only in general terms. Thus, thewidth 77 may range from a distance roughly equivalent to the depth of asingle groove 34 in one block, to a distance roughly equivalent to thedepth of two grooves 34 of opposing blocks. The width may also beroughly equivalent to the width of the web 36 of the beam 16 so that thewall engaging portion of the bracket may be oriented transversely to thewall structure. The length 78 may also vary depending upon therequirements of the wall structure (not shown). A typical width andlength for a wall engaging portion 62 may be on the order of about twoinches by about four inches, and a typical width and length for astructure engaging portion 60 may be on the order of about two inches byabout one-and-a-half inches. It will be appreciated that the bracket 19may be formed from material that may be modified or otherwise altered tofit a particular application. Thus, for example, the width and/or lengthof the wall engaging portion may be cut-to-length length or otherwisetailored at a jobsite without appreciably delaying or hinderingconstruction.

The structure engaging portion 60 of the bracket 19 also includesopposing surfaces 68, 70. However, in this embodiment, only opposingsurface 68 is configured to contact a portion of a structure (See, FIGS.40 and 42). As depicted, the structure engaging portion 60 is attachedto a lower surface of a structure “S” by an upwardly extending fasteneror fastening element 73. It is understood, however, that the attachmentsurface of the structure can be an upper surface, in which case theopposing surface 70 would contact the surface of the structure “S” andthe fastener would extend downwardly from surface 68 (shown in dashedlines). As shown in FIG. 42, the structure engaging portion 60 and thewall engaging portion 62 are planar and substantially orthogonal withrespect to each other. It is understood, however, that the wall engagingportion 62 and the structure engaging portion 60 need not be orthogonalto each other. They may be linearly aligned, for example. It is alsoenvisioned that the wall and structure engaging portions may be formedin other configurations. For instance, either portion 60, 62 may beformed with U-shaped profiles that enable the portions 60, 62 tostraddle sections of the structure and/or wall. That is the structureengaging portion may be formed so that it may straddle the bottom andside edges of a structure and the wall engaging portion may be formed toengage a wall structure at its front and/or rear surfaces. The structureengaging portion 60 is provided with an aperture 72 that may be usedwith a conventional fastener 73. For purposes of this application, theterm “fastening element” or “fastener” may include mechanical fastenerssuch as screws, nails, bolts, rivets, or their equivalents, and/oradhesives, weldments, or the like. Alternatively, the structure engagingportion 60 may be provided with an integral fastening element so thatthe portion 60 may be driven into or otherwise attached to a support.

Another embodiment of a bracket is depicted in FIGS. 44 and 45. As canbe seen, the bracket 200 generally comprises a structure engagingportion 202 and a support beam engaging portion 203. More specifically,the structure engaging portion 202 comprises a first member 204 and asecond member 206, which are angled with respect to each other to form agenerally “L”-shaped form. The first and second members may be providedwith apertures 208 that permit attachment to a structure with fasteningelements such as nail and threaded fasteners. It will be appreciated,though, that attachment may also be achieved with suitable adhesivesused in lieu of or in addition to fastening elements. The support beamengaging portion 203 comprises a web 210 and a pair of legs 212, 214,which are angled with respect to the web 210 to form a generally“L”-shaped form. The web 210 includes an aperture 220 that is accessiblethrough a slot 222 defined by edges 216 and 218 of legs 212 and 214,respectively. The aperture 220 and slot 222 are configured to slidinglyreceive a pair of ribs and a portion of a web of a support beam. Asdepicted in FIGS. 44, and 45, when a support beam is attached to thebracket, the support beam is able to move in a constrained mannerrelative thereto. This feature allows, the bracket to be attached atdifferent points along a structure as well as different points along abeam. Moreover, it allows a wall construction to be self-adjusting. Anapplication of bracket 200, a support beam 116, and a plurality ofbrackets 112 as can be seen in FIG. 53.

Another embodiment of a bracket is depicted in FIGS. 46 and 47. Thebracket 230 of this embodiment comprises a structure engaging portion232, a connecting web 234, and a support beam engaging portion 235 thatcomprises a rib 236 and a coupling element 238. The bracket 230 isconfigured and arranged to operatively connect a support beam (such asthe support beams depicted in FIGS. 11 a, 28, 44, and 45) to a support.As with the previously described bracket embodiment (200), the structureengaging portion 232 may be provided with apertures 240 that permit thebracket to be attached to a structure with conventional fasteningelements. Alternatively, the bracket may be attached to a support usingother known technologies and techniques. When the bracket 230 is used tooperatively connect a beam to a support, the coupling element 238 of thebeam engaging portion 235 is slidingly retained between one of thecoupling elements 186 and one of the pairs of ribs 182 a. Thusconfigured, a support beam is able to move in a constrained or slidingmanner relative thereto. This feature allows the bracket to be attachedat different points along a structure as well as along different pointsalong a beam. The bracket also permits a wall structure to beself-adjusting.

Referring now to FIGS. 48 and 49, an alternative embodiment of anattachment bracket 90 is depicted. Here, the bracket 90 is similar toearlier discussed bracket 18 (see FIGS. 4 and 22) in that it hasopposing walls 92, 94 that are connected to each other by a top wall orspan 96, and which retain a portion of a block in a constrainedrelation. However, in this embodiment, the shorter of the two walls 94is provided with an arm 98 that is movably attached thereto by aconnector 100, such as a rivet. As depicted in FIG. 48, the arm 98 is ina first position where it extends towards a block (not shown). In thisposition, the bracket 90 resembles bracket 18 (see FIG. 4) and may beattached at or near the underside of a structure in the usual manner,via the span 96.

In situations where it is not possible to easily attach the bracket 90to the underside of a structure, a user of the bracket 90 need onlyrotate the arm 98 to a second position so that it extends away from ablock (not shown) as depicted in FIG. 49. In this position, the bracketmay be attached to a vertical surface via the arm by a conventionalfastener, such as a nail or screw, which extends through an aperture102. Alternatively, the bracket may be secured to a vertical surface bya suitable adhesive. As will be appreciated, the bracket 90 may beoriented so that either one of the walls 92, 94 may be in confrontingrelation with the front or rear face of a block.

FIGS. 50-52 illustrate brackets and beams as shown in FIGS. 2 and 2 a asthey may be used in conjunction with blocks to form alternativestructures. Starting with FIG. 50, bracket 354 is depicted. The bracket354 is similar to previously described bracket 200 shown in FIGS. 44 and45 in that it generally comprises a structure engaging portion and asupport beam engaging portion. However, there are differences. Insteadof having a structure engaging portion that comprises a first member anda second member, structure engaging portion 356 of bracket 354 comprisesa single or first member 357. As depicted, the first member 357 isprovided with an aperture 360 that facilitates attachment to a structurewith fastening elements such as nails, threaded fasteners, or rivets. Itwill be appreciated, however, that an aperture or apertures need not bepresent in order to attach the bracket to a structure. The fasteningelement(s) may be driven through the first member, if desired.Additionally, it will also be appreciated that attachment may also beachieved with suitable adhesives, in lieu of, or in addition to,fastening elements. Continuing on, the support beam engaging portion 358comprises a web 362 and a pair of legs 364, 366, which are angled withrespect to the web to form a generally “L”-shaped form. The web 362includes an aperture 368 that is accessible through a slot 370 definedby edges 372 and 374 of legs 366 and 364, respectively. The aperture 368and slot 370 are configured to slidingly receive a leg portion 732 b andfoot 734 of a support beam 716 of FIGS. 51 and 52.

Generally, the bracket of FIG. 50 may be used with beams and blocks asshown in FIGS. 51 and 52 to form wall structures similar to wallstructures previously discussed. More specifically, support beam 716, asshown, comprises an elongated spine or web 718 and plurality of ribs 720and 722, 724 and 726, which are arranged in a substantially coplanar andcollateral relation so that the first pair of ribs 720, 722, which aresubstantially coplanar, extend away from each other in a manner similarto other embodiments already described. As shown, a first pair of ribs720, 722 are designed to engage the grooves 728 of one or more blocks ofa structure. As shown in FIG. 51, the support beams 716 may be orientedin a generally vertical direction, or as in FIG. 52, a generallyhorizontal direction. Note that in either orientation, the blocks wouldessentially be self-supporting.

In addition, the web also includes a second pair of ribs 724, 726 whichare also substantially coplanar and which extend away from each other.Note that the pairs of ribs 720, 722 and 724, 726 are in substantiallycollateral or parallel relation with respect to each other and arespaced apart from each other by a distance defined by the web 718. Thesupport beam 716 also includes a pair of pair of leg structures 730having leg portions 732 a-b that are similar to the leg structures ofFIG. 37 in that they extend rearwardly away from ribs 724, 726 and whichform a generally U-shaped channel therewith. The support beam differs,however, in that only one of the leg portions 732 b includes a foot 734.As depicted, the foot 734 extends laterally away from the leg portion732 b and is generally parallel with ribs 720, 722. As with theembodiment of FIGS. 2 and 2 a, the foot may be connected directly orindirectly to a support structure. However, as depicted, the beams ofFIGS. 51 and 52 are operatively connected to a structure by a pluralityof brackets 354, which are attached to suitable structural members. Withsuch an arrangement the beams, which are slidingly constrained by thebrackets, permit blocks to move without destroying the integrity of thestructure.

As shown in FIG. 53, a bracket 200 is used as part of a wall system tooperatively connect a support beam 116 to a structure “S”. Note that thelowermost course of blocks is supported by a horizontally oriented,elongated base, preferably in the form of an angle iron 83, which can beused with one or more support pads or footings 80 a, if desired. Theangle iron 83 includes an upper surface 86, that is configured toreceive one or more blocks thereon and a sidewall 88 that prevents theblock(s) from being shifted backwards. Optionally, the upper surfaceand/or the sidewall of the angle iron 83 may be provided with adhesivematerial to enable the block(s) to be secured thereto, which increasesthe strength and stability of the wall structure. Often, a completedwall structure will terminate in an upper course of blocks that isoffset from the structure “S”. In these situations, one or morecapstones or sills 113 may be used to provide a finished look, with thesills being positioned upon the upper course of blocks. As will beunderstood, the sills may be attached to the upper course of blocksusing known technologies and techniques, such as adhesives. Sometimes,there is a gap between a capstone or sill 113 and the structure “S”,through which moisture, debris, insects, etc. may pass. This gap can beeffectively closed using a sealing element 250 as depicted in FIGS. 54and 55.

The sealing element 250 of the present invention generally comprises abody having a plurality of flexible, resilient strips that provide aneffective seal between the sills or finish moldings and the structure.More specifically the sealing element 250 comprises a sealing panel 251that is formed by first and second strips 252 and 254 and an attachmentportion 255 that is formed by third and fourth strips 256 and 258. Theattachment portion 255 is operatively connected to the panel 251 suchthat the third and fourth strips extend therefrom in a generally radialrelation. As can be seen in FIGS. 54 and 55, the sealing element is inan unflexed state and the third and fourth strips 256 and 258 define anangle 262, which can range from about 15 degrees to about 165 degrees.The preferred range of the angle however is in the range of about 45degrees to about 75 degrees. The third and fourth strips 256 and 258 mayinclude beads or wales 260 that enable the sealing element to anchoritself into position. In use, the third and fourth strips 256 and 258 ofthe attachment portion 255 are pinched together and inserted into thegap between the wall and a structure, as shown in FIGS. 53 and 56. Asthe attachment portion 255 is seated, the first and second strips 252,254 of the panel 251 contact the surfaces of the sill 113 and thestructure “S” and exert normal forces there against. Thus, effectivelyseals the gap. As will be appreciated, the sealing element is maintainedin position by the beads 260 that, due to the resilient nature of thestrips, tend to catch against irregularities in the surfaces of the silland the structure “S” and resist movement. As will be appreciated, thesealing element 250 may be oriented so that the first and third strips252, 256 contact the sill 113 and the second and fourth strips 254, 258contact the structure “S”, if desired.

There may be times when it is not possible, practical, or desirable touse beams or the combination of beams and brackets, as previouslydescribed to operatively connect blocks to a structure. In such cases,blocks may be attached to a structure using only brackets. Generally, asshown in FIGS. 57-59, each bracket comprises a structure engagementportion and a block engagement portion that are spaced from each otherby a web. In one preferred embodiment, shown in FIG. 57, the bracket 754comprises a structure engagement portion 756 that is similar topreviously described structure engagement portions in that it isconfigured and arranged to act as a point of attachment to a structure,and comprises a member 766 having an aperture 768, with the apertureconfigured to be used in conjunction with a fastening element such as anail, screw or rivet. The bracket also comprises a web 762 and a panel760, which collectively serve to connect the structure engagementportion 756 to a block engagement portion 758, and which serve toposition a block a predetermined distance from a structure to which itmay be attached. While the structure engagement portion 756 and the web762 form a generally 90 degree angle therebetween, it will be understoodthat the angle may be modified depending upon the configuration of thestructure to which it is attached. Thus, for example, the angle could beacute or obtuse. The block engagement portion 758, which is connected tothe web, comprises a plurality of generally planar sections 759 a, 759b, 759 c, 759 d, and which are configured to cooperatively engageportions of one or more blocks such that forward and rearward movementof the blocks relative to the structure, is limited. This is achieved byforming some sections so that they are substantially coplanar with eachother and forming some sections so that they are substantially parallelto each other (when viewing the bracket on edge). Note that thosesections that are coplanar with each other extend away from the web inopposite directions, while those sections that are parallel to eachother and spaced from each other by a panel, need not be so restricted.Note also, that the sections are configured and arranged so that whenviewed from front, the sections do not overlap or superimpose upon eachother. As will be appreciated, this permits to bracket to bemanufactured from material such as metal and formed into the desiredconfiguration with a series of cuts and bends. It will be understood,however, that the bracket may be manufactured from different materials(eg. plastics) and formed using different techniques (eg. molding)without departing from the spirit and scope of the invention. In use, asshown in FIG. 60 (right side), the bracket 754 operatively connects twoblocks to a structure “S”.

Alternative embodiments of bracket 754 are depicted in FIGS. 58 and 59.As with the previously described bracket, these brackets 754′ and 754″,respectively, comprise a structure engagement portion, a web, and ablock engagement portion. The structure engagement portions are similarto the structure engagement portion of FIG. 57 in that they areconfigured and arranged to act as a point of attachment to a structure,and comprises a member 766′, 766″ having an aperture 768′, 768″respectively, with the aperture configured to be used in conjunctionwith a fastening element such as a nail, screw or rivet. Likewise, thebrackets also comprise a web 762′, 762″ which serve to connect thestructure engagement portion 756′, 756″ to a block engagement portion758′, 758″, respectively, and which serve to position a block apredetermined distance from a structure to which it may be attached. Ina departure from the web structure of FIG. 57, the webs of FIGS. 58 and59 include an additional aperture 764′, 764″ that is configured andarranged to act as a point of attachment to a structure (see, forexample, the left side of FIG. 60). As with the previously describeembodiment of FIG. 57, the angle formed by the structure engagementportion and the web (shown generally as 90 degrees) may be modifieddepending upon the configuration of the structure to which it isattached. The block engagement portions 758′, 758″, which are connectedto respective webs, each comprise a plurality of sections 759 a′ and 759b′, 759 a″ and 759 b″, which are configured to cooperatively engageportions of one or more blocks such that forward and rearward movementof the blocks relative to the structure, is limited. This is achieved byforming the sections so that they are generally coplanar to each other(when viewing the bracket on edge) and able to engage opposing surfacesin one or more blocks. A feature common to each of the sections 758 a′and 758 b′, 758 a″ and 758 b″ is that they have a thickness 776′, 776″that effectively spans the distance between the opposing surfaces intowhich they are positioned, such that forward and rearward movement ofthe blocks relative to the structure, is limited. In particular, theeffective thickness of each section 776′, 776″ of bracket 754′, 754″ isachieved by forming creases 772 in each section to form darts 770, whoseends define the extent of the effective thickness 776′. A strengtheningrib 774 may be provided for each section, if desired. The effectivethickness 776′ of the sections 770 of bracket 754′ is achieved byforming the sections so that they have high and low block contactingareas, preferably by curving the sections and more preferably by formingthe sections into the shape of arcs. FIG. 60 is a plan view of thebrackets of FIGS. 57 and 59 operatively connecting blocks of the presentinvention to a substructure.

It is to be understood that even though numerous characteristics andadvantages of various embodiments of the present invention have been setforth in the foregoing description, together with details of thestructure and function of various embodiments of the invention, thisdisclosure is illustrative only, and changes may be made in detail,especially in matters of structure and arrangement of parts within theprinciples of the present invention to the full extent indicated by thebroad general meaning of the terms in which the appended claims areexpressed.

1. A system for cladding a vertical support post, the system comprising:a plurality of beams, with each beam comprising: an elongate web; and, afirst pair of elongate ribs integrally formed with and extending awayfrom said elongate web in generally opposite directions; and, aplurality of blocks, each of said blocks comprising: an angularlysegmented front face; an angularly segmented rear face spaced from saidfront face by a distance defining the depth of said block; a topsurface; a bottom surface spaced from said top surface by a distancedefining the height of said block; first and second side surfaces spacedfrom each other, with each side surface extending from the front face tothe rear face and from the top surface to the bottom surface of saidblock, and with each side surface having a recess configured to receivea portion of an elongate rib of a support beam; wherein said blocks arearranged into a plurality of columns about the support post such thatside surfaces of horizontally adjacent blocks confront each other andtheir respective recesses are in general alignment; and, wherein saidbeams are positioned between said side surfaces of adjacent columns suchthat portions of said oppositely extending elongate ribs are able to bepositioned in respective recesses; whereby vertically adjacent blocksare arranged into columns and stabilized, and adjacent columns areoperatively connected to each other to form a cladding structure for thesupport post.
 2. The system of claim 1, wherein each said beam furthercomprises a second pair of elongate ribs extending away from saidelongate web in generally opposite directions, with said first pair ofelongate ribs spaced from said second pair of elongate ribs by adistance defining the span of said elongate ribs.
 3. The system of claim2 wherein said span of said elongate ribs is at least as great as adistance measured between said recesses of said side surfaces, and saidrear face of each of said plurality of blocks.
 4. The system of claim 2wherein said span of said elongate ribs is less than a distance measuredbetween said recesses of said side surfaces, and said rear face of eachof said plurality of blocks, and wherein at least one of said pairs ofelongate ribs is resiliently deformable such that when support beams arepositioned between said vertically adjacent columns, at least oneelongate rib of said pair of resiliently deformable elongate ribsdeforms, thereby increasing said span to at least as great as saiddistance between said recesses and said rear face of each of saidplurality of blocks.
 5. The system of claim 1, wherein each elongate ribof said first pair of elongate ribs further comprises an angled flangefor guiding said elongate ribs into said recesses.
 6. The system ofclaim 1, wherein at least one portion of beam is attached to thevertical support post.
 7. The system of claim 1, further comprisingadhesive material positioned between at least two adjacent blocks. 8.The system of claim 1, wherein said blocks comprise composite masonrymaterial.
 9. The system of claim 1, wherein the angularly segmentedfront face of at least one block comprises a split face.
 11. A systemfor cladding a vertical support post, the system, the system comprising:a plurality of beams, with each beam comprising: an elongate web; and, afirst pair of elongate ribs integrally formed with and extending awayfrom said elongate web in generally opposite directions; a plurality ofblocks arranged in columns, each of said blocks comprising: a frontface; a rear face spaced from said front face by a distance defining thedepth of said block; a top surface; a bottom surface spaced from saidtop surface by a distance defining the height of said block; first andsecond side surfaces spaced from each other, with each side extendingfrom the front face to the rear face and from the top surface to thebottom surface of said block, and with each side surface having a recessconfigured to receive a portion of an elongate rib of a support beam;and, at least one bracket comprising a beam connecting portion and asupport beam attaching portion; wherein said blocks are arranged into aplurality of columns about the support post such that side surfaces ofhorizontally adjacent blocks confront each other and their respectiverecesses are in general alignment; wherein said beams are positionedbetween said side surfaces of adjacent columns such that portions ofsaid oppositely extending elongate ribs are able to be positioned inrespective recesses; wherein portions of at least one of the beams isslidingly connected to said support beam attaching portion of saidbracket; and, wherein said bracket is attached to the support post;whereby vertically adjacent blocks are arranged into stabilized columns,adjacent columns are operatively connected to each other to form acladding structure, and the cladding structure is connected to thesupport post.
 12. The system of claim 11, wherein the first and secondside surfaces are generally planar and non-parallel.
 13. The system ofclaim 11, wherein each said beam further comprises a second pair ofelongate ribs extending away from said elongate web in generallyopposite directions, with said first pair of elongate ribs spaced fromsaid second pair of elongate ribs by a distance defining the span ofsaid elongate ribs.
 14. The system of claim 13 wherein said span of saidelongate ribs is at least as great as a distance measured between saidrecesses of said side surfaces, and said rear face of each of saidplurality of blocks.
 15. The system of claim 13 wherein said span ofsaid elongate ribs is less than a distance measured between saidrecesses of said side surfaces, and said rear face of each of saidplurality of blocks, and wherein at least one of said pairs of elongateribs is resiliently deformable such that when support beams arepositioned between said vertically adjacent columns, at least oneelongate rib of said pair of resiliently deformable elongate ribsdeforms, thereby increasing said span to at least as great as saiddistance between said recesses and said rear face of each of saidplurality of blocks.
 16. The system of claim 11, wherein each elongaterib of said first pair of elongate ribs further comprises an angledflange for guiding said elongate ribs into said recesses.
 17. The systemof claim 11, wherein at least one portion of beam is attached to thevertical support post.
 18. The system of claim 11, further comprisingadhesive material positioned between at least two adjacent blocks.
 19. Asystem for cladding a vertical, load bearing support post of an elevatedstructure, the system comprising: a plurality of beams, with each beamcomprising: an elongate web; and, a first pair of elongate ribsintegrally formed with and extending away from said elongate web ingenerally opposite directions; a plurality of composite masonry blocksarranged in columns, each of said blocks comprising: a front face; arear face spaced from said front face by a distance defining the depthof said block; a top surface; a bottom surface spaced from said topsurface by a distance defining the height of said block; first andsecond side surfaces spaced from each other, with each side extendingfrom the front face to the rear face and from the top surface to thebottom surface of said block, and with each side surface having a recessconfigured to receive a portion of an elongate rib of a support beam;and, a bracket comprising a beam connecting portion and a support beamattaching portion; wherein said blocks are arranged into a plurality ofcolumns about the support post such that side surfaces of horizontallyadjacent blocks confront each other and their respective recesses are ingeneral alignment; wherein said beams are positioned between said sidesurfaces of adjacent columns such that portions of said oppositelyextending elongate ribs are able to be positioned in respectiverecesses; wherein portions of at least one of the beams is slidinglyconnected to said bracket; and, wherein said bracket is attached to thesupport post; whereby vertically adjacent blocks are arranged intostabilized columns, adjacent columns are operatively connected to eachother to form a cladding structure, and the cladding structure isconnected to the support post.
 20. The system of claim 20, wherein atleast one composite masonry block comprises an angularly segmented frontface.
 21. A method of cladding a vertical, load bearing support post ofan elevated structure, the method comprising: a. providing a pluralityof blocks, with each block comprising: an angularly segmented frontface; an angularly segmented rear face spaced from said front face by adistance defining the depth of said block; a top surface; a bottomsurface spaced from said top surface by a distance defining the heightof said block; and, first and second side surfaces spaced from eachother, with each side surface extending from the front face to the rearface and from the top surface to the bottom surface of said block, andwith each side surface having a recess located between the front andrear surfaces; b. providing at least one beam, with the beam comprisingan elongate web and a first pair of elongate ribs integrally formed withand extending away from said elongate web in generally oppositedirections; c. arranging the blocks about the support post such thatside surfaces of horizontally adjacent blocks confront each other andtheir respective recesses are in general alignment; d. positioning thebeam so that portions of said oppositely extending elongate ribs areable to be positioned in respective recesses; and, e. connecting atleast one beam to the support post.
 22. A method of cladding a vertical,load bearing support post of an elevated structure, the methodcomprising: a. providing a plurality of blocks, with each blockcomprising: an angularly segmented front face; an angularly segmentedrear face spaced from said front face by a distance defining the depthof said block; a top surface; a bottom surface spaced from said topsurface by a distance defining the height of said block; and, first andsecond side surfaces spaced from each other, with each side surfaceextending from the front face to the rear face and from the top surfaceto the bottom surface of said block, and with each side surface having arecess located between the front and rear surfaces; b. arranging theblocks in a first horizontal course about the support post such thatside surfaces of horizontally adjacent blocks confront each other andtheir respective recesses are in general alignment; and, c. securing asecond horizontal course of blocks to the first horizontal course ofblocks.
 23. The method of claim 22, wherein the step of securing asecond horizontal course of blocks to the first horizontal course ofblocks comprises the step of positioning adhesive material between thetop surface of at least one block of the first horizontal course ofblocks and the bottom surface of at least on block of the secondhorizontal course of blocks.